UDOT Construction Inspection Guide - Chapter 6 by TLCS

UDOT Construction Inspection Guide CHAPTER 6: Structures

Published November 2012

Table of Contents Structures 6.1

Structures Introduction

Bridges, retaining walls, culverts & other structures play a major role in UDOT’s transportation system…

Prosecution and Progress 00555 – Project Schedule

The purpose of this section is to provide basic guidance to schedule of work. Limitations to ….

6.2

Structural Survey

Survey is a critical component of structural work and ahs a direct impact on structural geometry, load capacity, clearances….

6.4 Structural Elements and Materials

The most common of structural materials is concrete and steel. This section addresses the most common structural materials and its use on major ….

02645 – Precast Concrete Culverts

This item includes the materials, fabrication and placement for precast concrete box culverts…

02646 – Concrete Box Culvert

This item includes the materials and construction of cast in place concrete box culverts…

02861 – Precast Retaining/Noise Walls

This item includes the materials, fabrication and placement for precast noise retaining walls…

02893 – Overhead Signs/VMS Structures

This item includes the materials, fabrication and installation of structural steel materials used…

03211 – Reinforcing Steel and Welded Wire

6.3

Structural Foundations, Excavation & Backfill

02056 – Str. Embankment, Backfill Borrow This section covers inspection of the structural backfill items for bridges, box culverts… 02221 – Remove Structure & Obstruction To remove all structures and obstructions, the contractor must remove, dispose of, or…

02455 – Driven Piles

This item includes specifications for the materials, fabrication and installation of driven piles….

02466– Drilled Shafts

This item includes specifications for the materials, fabrication and installation of drilled shaft foundations….

02832S – Select Backfill for MSE Walls

Mechanically stabilized earth (MSE) is soil constructed with artificial reinforcing, used for….

This item includes the materials and placement for reinforcing steel and welded wire fabric used in…

03310 – Structural Concrete

This item includes the materials and placement for structural concrete for cast in place applications…

03390 – Concrete Curing

This item includes the specifications for the curing of concrete specific to concrete structures….

03392 – Penetrating Concrete Sealer

This item includes materials used as a preventive treatment to seal water and deicing salts….

03412 –Pre-stressed Concrete

This item includes the materials and placement for structural concrete that includes pre-stressed….

05120 –Structural Steel

This item includes specifications for the materials, fabrication and installation of structural steel….

05822 –Bearings

This item includes the materials and placement for bearings used in conjunction with bridge girders…

09972 – Painting Structural Steel

This item includes specifications for the materials and application of painting systems for structural….

Table of Contents - Continued

6.5 Bridge Decks, Approaches and Joints 02982 –Bridge Concrete Grinding

This item includes procedures for grinding new concrete deck and approach slabs systems. Grinding of the…

03311 – Joint Closure

A bridge deck joint closure consists of removing the existing joint system, installing reinforcing steel and …

03339 – Precast Concrete Deck Panel

Precast deck panels are used on both new construction and deck replacement projects …..

03372- Thin Bonded Polymer Overlay

This item includes procedures for overlaying concrete bridge decks with a thin polymer material and ….

05832 – Expansion Joint

This item includes the materials and placement for expansion joints and associated forming false work ….

05835 – Modular Expansion Joint

This item includes the materials and placement for modular expansion joints and associated forming….

07105 – Waterproofing Membrane

This item includes procedures for applying a waterproofing membrane for bridge decks and….

6.6 Structural Repairs and Modifications 03605 – Approach Slab Jacking

This item includes the materials and construction requirements for lifting (jacking) of bridge….

03924 – Structural Concrete Repair/Sealing

This item includes the materials and construction requirements for repairs and rehabilitation to ….

03932 – Concrete Slope Protection Repair

This item includes the materials and construction requirements for repairing slope protection….

03933- Parapet End Modification

This item includes the materials and construction requirements for repairs to bridge parapet ends ….

03934 – Structural Pothole Patching

This item includes the materials and construction requirements for repairs and patching of potholes….

05831 – Expansion Joint Modification

This item includes the materials and construction requirements for replacement of bridge expansion….

07921 – Sealing Existing Concrete Slope Protection

This item includes the materials and construction requirements for sealing slope protection….

07922 – Relief Joint Crack Sealing

This item includes the materials and construction requirements for sealing concrete relief joints….

09991 – Cleaning & Repainting Structural Steel This item includes the materials and construction requirements for cleaning and repainting ….

09992 – Cleaning and Overcoating Structural Steel This item includes the materials and construction requirements for cleaning and overcoating….

CHAPTER 6: STRUCTURES

6.0 INTRODUCTION

Chapter 6

Bridges, retaining walls, culverts and other structures play a major role in UDOT’s transportation system. They directly influence traffic operations, safety and funding needs. The quality of structural construction can have a tremendous effect on the life and safety of these structures. Construction Engineers and Inspectors play a vital role in ensuring that structural projects are built to plans and provide expected performance. The sections of this Structures Chapter closely follow the corresponding section in the Standard Specifications. The intent of this chapter is not to repeat the specifications, but to offer an overview of the general intent of the specification, and guidelines for Inspectors to ensure work has been properly completed. All section numbers refer to the Standard Specifications 2012 edition and Supplements. The first duty of an Inspector is to become thoroughly familiar with the contract plans, standard plans, special provisions, standard specifications, and any right-of-way agreements that apply to the particular project. Each section of this chapter is referenced to a specific standard specification and includes descriptions for the following:

General Overview Briefly describing the related work and intent of the specifications, and common issues for related section covered.

Pre-Construction Checklist Summarizing necessary documentation that must be submitted with the related section prior to construction of the item.

Inspection Checklist Describes the actions the Inspector should take during construction activities to ensure that the item is properly constructed and documented.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 1

UDOT

Construction Inspection Guide

^ƚƌƵĐƚƵƌĂů Žnline Presentations: InspecƚŽƌƐ YƵĂůŝĨŝĐĂƚŝŽŶ WƌŽŐƌĂŵ Ͳ ϮϲϬϬ ƐĞƌŝĞƐ

Level One 1. Plans, Specs and Estimates 2. Role of the Inspector 3. Structural Concepts 4. Structural Geometry and Layout 5. Structure Types and Terminology

Terminology: (Structures) Terminology for bridges, retaining walls, culverts and other structures can be very confusing. The following graphics show common terminology of bridge elements:

Page | 2

CHAPTER 6: STRUCTURES

CHAPTER 6

6.1 PROSECUTION AND PROGRESS – GENERAL INTRODUCTION Structural work can be the primary scope of a project or a component of a broader project. In either situation, the requirements of the prosecution and progress section of the project need to be reviewed and implemented. The schedule and limitations of operations for the structural work are important factors in the success of the project. For example, many structure projects are now using techniques such as accelerated bridge construction with limitations to traﬃc closures. The Inspector has a responsibility to understand and enforce these requirements.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 3

UDOT

Construction Inspection Guide

A) PROSECUTION & PROGRESS - SECTION 00555 General The purpose of this section is to provide basic guidance to schedule of work, limitations to work and payment schedule.

Contractor Submittals The contractor must submit a baseline project schedule within 14 days of notice of award for approval by the Engineer using a Primavera 5.0 or other approved format.

Documentation and Payment All Inspectors should be familiar with inspection and documentation requirements for prosecution and progress including project schedule and limitations of operations. A schedule for payments is also required. 00555: PROSECTUTION & PROGRESS

Pre-Inspection Submittals & Items  Contractor must submit a baseline project schedule within 14 days of notice of award and prior to starting work. The project schedule should include components for major structural work such as excavation, foundations, superstructure erection, and backﬁll. The baseline schedule must be reviewed and accepted by the Engineer prior to beginning work.  Contractor and Inspector should be familiar with project plans and speciﬁcations relating to schedule and limitations of structural work items.  The Inspector and contractor must be familiar with any requirements for accelerated construction methods. They are encouraged to contact UDOT’s structures division for any questions.

Inspection & Field Documentation  Contractor and Inspectors must have copies of the plan package including plans, standard speciﬁcations and special provisions readily available in the ﬁeld for review and interpretation of issues as they arise.  Inspectors must maintain daily inspection records giving a narrative of work accomplished, and resources of labor, equipment and materials used. The Inspector diaries may become an important document in the event that the project schedule changes and change orders are required.  Coordinate all accelerated bridge construction work with UDOT’s Structures Division.

Page | 4

CHAPTER 6: STRUCTURES

CHAPTER 6

6.2 STRUCTURAL SURVEY â&#x20AC;&#x201C; SECTION 01721 General Survey is a critical component of structural work and has a direct impact on structural Geometry, load capacity, clearances, drainage, ride and safety. The inspector should be familiar with the requirements of standard specification 01721 (Survey) as it pertains to structural items including drainage structures, bridges, box culverts and retaining walls. In many cases, survey accuracy and tolerances may be greater for structural work than roadway and other items. For example, bridges are typically designed and dimensioned on plans to a 1/16th of an inch. Small survey errors have the potential for significant problems with overall fit and clearance of a bridge or other structure. Structural plans typically will show dimensions using a variety of perspectives including plan views (looking down), elevation views (looking from side), and cross sections. Dimensions of these perspectives are adjusted to include slope, curvature and profile. Some of the most common field errors relating to structural geometry are those associated with errors in misinterpretation of plan dimensions. It is important for the surveyor and Inspector to understand and review the plans and to ask questions if needed, especially when utilizing precast elements. Since approximately 2005, UDOT has increased its use of precast deck panels and other precast components. The fit of these components requires even greater precision than cast in place construction. The Inspector and Resident Engineer should pay particular attention to survey practices for precast elements.

Submittal Requirements and Common Issues The contractor is responsible to submit a written description of the survey plan including manpower, equipment and data storage prior to starting survey work.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 5

UDOT

Construction Inspection Guide

01721: STRUCTURAL SURVEY

Pre-Inspection Submittals & Items  Contractor must submit a survey plan prior to starting work containing anticipated personnel, equipment, methodology and data storage processes.  Inspector to communicate survey efforts with UDOT’s Central Materials and Structures Divisions for structures using precast components.

Inspection & Field Documentation  Inspector to observe structural survey and notify the Engineer and Contractor of any potential problems found with general structural layout, geometrics, vertical clearance, horizontal clearance and other related issues.  Inspector is to document survey work activities.  Inspector to document any ﬁt problems or issues with the ﬁt of precast components.

6.3 STRUCTURAL FOUNDATIONS, EXCAVATION AND BACKFILL

A) EMBANKMENT, BORROW 02056 General This section covers inspection of the structural backfill items for bridges, box culverts, foundations, pipe culverts, retaining walls, drains and other structures. See standard specification 02317 for related requirements for Structural Excavation. The stability of a structure is directly related to having adequate backfill materials to support the structure. Page | 6

CHAPTER 6: STRUCTURES

AND

BACKFILL (STRUCTURAL) – SECTION

CHAPTER 6 The use of acceptable materials that are compacted to proper tolerances is an important component of structural construction. In particular, this is critical to structures without deep foundations such as pipes, retaining walls and bridges on spread footings. The Inspector plays a vital role in ensuring the quality of materials and construction methods for structural embankment, backfill and borrow.

02056: EXCAVATION & BACKFILL

Pre-Inspection  Backfill Materials: Ensure that temporary erosion control measures are in place, SWPPP materials used have been certiﬁed, maintained throughout construction, and subsequently removed after completion.  Site Preparation: Clearing and grubbing within the designated area is completed before starting excavation. No organic material remains that could contaminate the embankment or backﬁll. Refer to Section 02231.  Safety: Contractor submitted proposed method of blasting, delay pattern, explosive types, and type of blasting mat cover, if applicable. Contractor has complied with all applicable regulations when excavating and trenching, such as the shoring system standards established by OSHA. Refer to Section 00820. If applicable, contractor provided a cofferdam for underwater work and removed all cofferdams, sheeting, and bracing when no longer needed.

Inspection  Excavation and Disposal: Contractor has furnished copies of disposal permits or agreements, or letter certifying the destination of the material, if applicable.  Materials Inspection: Materials are tested in accordance with the MS&TR and material placement is in conformance within specified lift thicknesses and compaction requirements. Finish to the design grade and within specified tolerances.  Use of On-Site Materials: Contractor obtained written approval before using excavated materials found on the work site that are suitable for completing other bid items of work and before excavating material outside grading limits. Contractor established an approved method of measuring quantity of on-site material used.  Documentation: The Inspector along with the Materials Testing Technician shall take measurements for compaction of the backfill materials and document that minimum requirements have been met.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 7

UDOT

Construction Inspection Guide

B) REMOVE STRUCTURE

AND

OBSTRUCTION - SECTION 02221

General To remove all structures and obstructions, the contractor must remove, dispose of, or salvage buildings, fences, structures, pavements, curb, gutter, driveways and approaches, sidewalk and similar hard surfaces, abandoned pipelines or utility items and other obstructions that interfere with construction. This includes obstructions such as foundations, bridges, culverts, guardrail, concrete work, septic tanks, and trees. The contractor should salvage as specified in the plans, or dispose of in a manner approved by the Engineer. The Inspector should ensure that the contractor has removed all organic materials in any areas to be backfilled or compacted and assure the quality of the underlying materials.

Submittal Requirements Prior to construction, request copies of the following documents: 1. Utility Location and Protection (Blue Stakes receipt form). 2. Documentation for Wasted Materials Disposal. 3. Environmental Control requirements, including SWPPP certifications. 4. Demolition Permits from the Health Department or local government.

Common Issues Document these common contractor mistakes: 1. Grade not cut to the required tolerance. 2. All organic materials and obstructions are not removed. 3. Improper material disposal, on or oďŹ&#x20AC; site. 4. Drainage is not maintained. 5. Contamination of materials to be left on-site for future use. 6. Remaining grade will not support new structure.

Page | 8

CHAPTER 6: STRUCTURES

CHAPTER 6 02221: REMOVE STRUCTURE & OBSTRUCTION

Pre-Inspection  Contractor has obtained all necessary local government permits for demolition, as required when demolishing buildings or homes.

Inspection  Obstructions are removed to required depth below surface or broken to required size limits if allowed to remain in place.  Organic materials have been removed and the quality of the underlying materials has been assured.  Areas are backﬁlled and compacted as speciﬁed.

C) DRIVEN PILES - SECTION 02455 General This item includes specifications for the materials, fabrication and installation of driven pile foundations. Driven piles are commonly used on bridge structures to transfer the weight of the bridge to suitable soils and earth materials. In addition, they resist movement of the bridge during earthquakes. Poor quality of the pile materials and installation can result in settlement and possible collapse of the bridge. The Inspector plays a vital role in the quality of driven pile construction.

Pile Materials Driven piles can be made of steel, timber or concrete. The most common piles used are steel, and commonly installed using circular (pipe shape) or H shaped beams (H pile). Requirements for the material properties of the piles are shown in the bridge plans and are critical to their ability to support

UTAH DEPARTMENT OF TRANSPORTATION

Page | 9

UDOT

Construction Inspection Guide

the bridge. The Inspector and Resident Engineer should contact a Structural Engineer before allowing any substitution of pile materials or shapes other than what is shown on the plans. Contractors will often ask to substitute pile shapes, thicknesses and grade for cost or availability reasons. However, small changes in wall thicknesses or grade of steel can have dramatic impacts on the pile capacity. The contractor is required to submit material certifications prior to delivery of the piles. Buy America requirements apply to Federally funded projects.

Pile Capacity Driven piles support the bridge loads through a combination of bearing capacity at the ends (tip) and side friction with the soils along the sides of the pile. Piles are driven by mechanical equipment (pile driver). The pile driving operation loosens (liquefies) the soil as the pile is being driven. Once the pile driving has been completed, the soils will swell against the pile resulting in a higher load capacity than when the pile is being driven. The piles ability to support weight is measured by electronic equipment called a Pile Driving Analyzer (PDA). The PDA is used to take measurements on a test pile while driving and again (re-strike) at least 24 hours later when the surrounding soils have firmed up. The bridge plans typically show an estimated driving resistance and a minimum pile resistance that must be reached at “re-strike”. Bridge plans will also show the estimated number of piles, layout and driving elevations. Bridge foundations are designed to resist the calculated weights (loads) of the bridge in comparison to expected soil conditions. However, soil capacities can vary dramatically and the actual pile depths and quantities may vary from what is estimated on the plans. The Pile Driving Analyzer is used on a “test pile” to determine the actual pile capacity depths and quantities. The Inspector needs to take blow count readings quantifying the number of blows required to drive the pile for at least 1 foot increments. The blow counts are compared to the test pile to correlate to actual resistance readings.

Driving Equipment The type and size of hammer used to drive piling needs to match the size and strength of the pile being driven. This is similar to using a hammer size that matches the size of a nail being driven. Too small of a hammer may not be able to eﬃciently drive the pile, and too large of a hammer may damage the pile. The contractor is required to submit a detail of pile driving equipment that they will be using for approval. This information will also be needed for the PDA Page | 10

CHAPTER 6: STRUCTURES

CHAPTER 6 to measure the capacity of the pile. Inspectors should document the pile driving equipment being used and take photographs.

Certifications Material certifications are needed for the driven piles. Most driven piles are made of structural steel and are commonly available in standard shapes, grades and dimensions from both domestic and foreign manufacturers. Steel is manufactured by a steel mill (manufacturer) from raw materials into common shapes and sizes. A steel supplier or fabricator typically resells, reshapes or modifies the steel into the final shape and configuration. The steel production mill and fabricator may or may not be the same company and the Inspector is responsible for certifications for both the materials and fabrication process. Certified Mill Test Reports (MTR) must be submitted for all structural steel materials, including those manufactured outside the United States. Additional “Buy America” requirements apply for Federally funded projects or if specified. The fabricator of structural items must be AISC – Major Steel Bridge (CBR) certified if components are used on a bridge structure. UDOT’s Central Materials Division oversees the quality process for the manufacturing and fabrication of structural steel items. The Resident Engineer and Inspector are responsible to notify them of structural steel items used on the project. Steel piles commonly are available in lengths less than 50 feet to assist in shipping. Welding of pile sections is commonly required. Welding should be performed by welders who are certified by the American Welding Society (AWS) for structural steel AWS d1.1 or higher. Unloading, Handling and Storing Upon delivery of the piles, the Inspector should look for signs of damage and verify that the material information matches what is shown on the mill certifications. Any discrepancies should be brought to the attention of the Resident Engineer. The unloading of the steel should be accomplished by means of equipment and methods

UTAH DEPARTMENT OF TRANSPORTATION

Page | 11

UDOT

Construction Inspection Guide

which will not damage the members and should be moved by use of slings and wood blocks to prevent damage to the flanges. Steel members are never to be dropped. Piles should be stored in a manner that will prevent injury from moving or falling.

Construction Driven piles should not be driven until the excavation is complete unless specified on the plans. The Inspector should ensure that any exposed side slopes meet OSHA safety standards. The piles are to be driven in a vertical alignment unless noted otherwise. Welding of pile section must be performed by a certified welder. During the driving operations, the Inspector should visually look for signs of distortion of the pile or misalignment. Any concerns should be brought to the attention of the Resident Engineer. A minimum of 2" of exposed pile should extend above the ground and into the bottom of the abutment.

Test Pile and Acceptance The contractor is required to drive a test pile prior to driving additional piles and compare actual resistance to ensure it meets or exceeds the design resistance. Resistance readings are measured by an independent testing firm who is approved by UDOT. Blow counts should be taken and recorded for every foot of the test pile. If the minimum resistance canâ&#x20AC;&#x2122;t be reached at the re-strike a Structural Engineer should be contacted for further instructions such as adding additional piles or driving to a deeper depth.

Submittal Requirements The contractor shall submit the following for approval: 1. Project Schedule with milestones for driven piles. 2. Buy America certification (if applicable). 3. Material certifications, and mill test reports (MTR). 4. Certifications of Welders. 5. Pile Driving Equipment data. 6. Selection of approved Pile Driving Analysis firm. 7. Buy America Certification/Documentation. Page | 12

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues 1. Missing approvals and certifications. 2. Contractor wants to substitute with diﬀerent pile shapes and sizes. 3. Damage of piling during shipment or placement. 4. Improper welding, cutting, bending or modification in field. 5. Improper fit or alignment. 6. Excessive deflection, movement or stability.

02455: DRIVEN PILES

Pre-Inspection  Contractor to Submit Project Schedule including pile driving tasks.  Contractor to Submit Mill and Material Certifications.  Contractor to submit Pile Driving Equipment using UDOT form.  Contractor to submit certifications for welder qualifications.  Selection of an approved Pile Driving Analysis Firm.  Safety Plan for handling piles and driving process.

Field Inspection & Documentation  Visual veriﬁcation of piles for damage or defects.  Inspector to document and verify fabrication certiﬁcation with pile labels.  Pile alignment.  Splice details and welding procedures.  Maintain records of drill depths, conditions and quantities used.  Contact Structural Engineer for any abnormal issues.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 13

UDOT

Construction Inspection Guide

D) DRILLED SHAFTS - SECTION 02466 General This item includes specifications for the materials and construction of drilled shaft foundations. Drilled shaft foundations are commonly used on bridge structures to transfer the weight of the bridge to suitable soils and earth materials. In addition, they resist movement of the bridge during earthquakes. Poor quality of the drilled shaft can result in settlement and possible collapse of the bridge.

Drilled Shaft Construction Drilled shaft foundations are constructed by mechanically drilling a shaft into the earth and placing a reinforcing steel cage and filling with concrete. The reinforcing extends into the abutment or foundation footing to transfer the load from the bridge. The Inspector and Resident Engineer are responsible to ensure that the shaft is safely drilled to the recommended depth and quality using approved materials. The Inspector should ensure that the materials are certified, shaft alignment is true, and reinforcement and concrete are properly placed. The Inspector should also ensure that concrete has cured a suďŹ&#x192;cient amount of time before drilling an adjacent shaft.

Drilled Shaft Materials Drilled shafts are strengthened by adding reinforcing steel and concrete. The reinforcing steel must meet material specifications and certifications as specified in section 03211. The concrete must meet approved mix designs and testing during placement for Portland cement concrete as described in section 03055.

Drilling Equipment The contractor is required to provide equipment that can safely and eďŹ&#x192;ciently drill holes to the required depth, diameter, and alignment. The use of steel casing is Page | 14

CHAPTER 6: STRUCTURES

CHAPTER 6 commonly used to prevent the shafts from collapsing during drilling. The drilling equipment should also be capable of removing the casing.

Submittal Requirements The contractor shall submit the following for approval: 1. Procedures for placing concrete under water. 2. Certifications for reinforcing steel. 3. Mix design for concrete.

Common Issues 1. Certifications and procedures not submitted on time. 2. Equipment breakdowns. 3. Shaft sides collapse after drilling and removal of casing. 02466: DRILLED SHAFTS

Pre-Inspection  Concrete Mix Design approved.  Reinforcing Steel approved.  Procedure for Placing under water.

Field Inspection & Documentation  Drilled to estimated depth.  Shaft straight and true.  Materials testing of concrete.  Proper placement of concrete and vibration.  Maintain records of blow counts, driven depths and quantities used.  Contact Structural Engineer for any abnormal issues.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 15

UDOT

Construction Inspection Guide

E) SELECT BACKFILL

FOR

MSE WALLS - SECTION 02832S

General Mechanically stabilized earth (MSE) is soil constructed with artificial reinforcing. It can be used for retaining walls, bridge abutments, dams, seawalls, and dikes. Only select backfill should be used for MSE retaining walls. The reinforcement materials of MSE can vary widely from steel grids to geotextiles. The Inspector should ensure that materials used meet plan specifications and that density requirements are met.

Submittal Requirements Prior to performing inspection, request copies of the following documents: 1. Approved job mix formula (gradation targets). 2. Weight Tickets for Measurement & Payment.

Common Issues Document these common contractor mistakes: 1. Material placed on snow or frozen grade. 2. Drainage is not maintained. 3. Lift thickness or moisture is incorrect. 02832: SELECT BACKFILL FOR MSE WALLS  Approved job mix formula.  Density requirements have been met.  Soil classification, gradation, and other soil requirements satisfy the materials specification.  Material placement in conformance within specified lift thickness.

Page | 16

CHAPTER 6: STRUCTURES

CHAPTER 6

6.4 STRUCTURAL ELEMENTS AND MATERIALS – GENERAL INTRODUCTION The most common of structural materials are concrete and steel. This section addresses the most common structural materials and its use on major structural elements such as culverts, girders and other components.

A) PRECAST CONCRETE BOX CULVERTS - SECTION 02645 General This item includes the materials, fabrication and placement for precast concrete box culverts. These structural systems are pre-fabricated using reinforced concrete materials. Cast in place box culverts are addressed in other specifications. Associated work may include cast in place concrete for wing walls and other components. Precast box culverts are commonly used as buried drainage structures to convey water underneath the roadway. They are also used as pedestrian, wildlife and utility structures. Precast systems oﬀer advantages such as an alternative where ready mix concrete suppliers are not available or construction schedules are limited. Disadvantages include separation and leaking of joints if they are not properly installed. Precast box culverts consist of reinforced concrete sections that are shipped to the project site and joined to achieve the desired culvert length. Fabrication is typically completed by a pre-approved fabricator and inspected for approval by UDOT’s Central Materials Division prior to shipment. UDOT’s central materials division is responsible for the quality control of the pre-casting process including materials, forming, casting and curing of precast concrete structural components. As such, the Resident Engineer or Inspector should notify UDOT’s central materials and structures division of contractor schedule to fabricate precast culvert systems. The Resident Engineer will receive “shop drawings” submitted for approval prior to fabrication. The Resident Engineer is responsible to forward the SE drawings to the designer of record and also notify UDOT’s central materials and structures divisions.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 17

UDOT

Construction Inspection Guide

Once cured and approved, the precast components will be shipped with a label certifying the quality and approval. The field Inspector should verify the presence of this acceptance label prior to placement on the project site. Once the finished product leaves the precast yard, it becomes the responsibility of the field Inspector who will ensure that the component is handled properly and not damaged. The Inspector will need to ensure that the bedding surface and materials are properly prepared prior to placing the culvert segments. He/she will ensure that each segment is properly fit with adjacent segments, joint materials properly installed, and the structure is backfilled to specifications. The Inspector should ensure that the culvert is installed to dimensions and specifications in the plan package. This includes proper depths, cover, flow, and joint tolerances.

Submittal Requirements Prior to fabrication and installation, the contractor shall submit the following: 1. Project Schedule that included milestones and dates for the fabrication, shipping and placement of precast concrete structural components. 2. Shop Drawings for approval of Precast components by the Design Engineer with notification to UDOTâ&#x20AC;&#x2122;s Structures Division. 3. Notification to UDOTâ&#x20AC;&#x2122;s Central Materials Lab and Resident Engineer of schedule to form and cast the precast components. 4. Certification of materials and fabrication process to be approved by UDOT Central Materials Division prior to fabrication. 5. Erection Plan.

Common Issues Document these common contractor issues: 1. Shop Drawings are missing or delayed. 2. Approvals, certifications, and inspection not coordinated with Central Materials, lead designer or Structures Division. 3. Finish of concrete is substandard. 4. Grade is not adequately prepared or compacted. 5. Finished product is damaged during shipment or placement. 6. Structural component is not lifted or placed in a safe manner. Page | 18

CHAPTER 6: STRUCTURES

CHAPTER 6 7. Joints are not properly fitted to acceptable tolerances. 8. Contractor fails to compact backfilling materials. 9. Components are not installed to acceptable dimensions or fit. 02645: PRECAST CONCRETE BOX CULVERTS

Pre-Inspection  Contractor to submit project schedule that includes precast items.  Contractor to Submit Shop Drawings for approval.  Inspector to coordinate inspection with UDOT Lead Designer, Central Materials and Structures Division.  Central Materials Inspector to ensure materials certiﬁcations, mix designs, forming, placement, curing and overall fabrication process.  Fabricator to ensure that incidental items such as parapet ties, fence post, anchor bolts and other details are included prior to casting concrete.  Erection Plan is required prior to placement.

Field Inspection & Documentation  Central Materials to certify fabrication and approval of component.  Inspector to document and verify fabrication certification.  Ensure bedding material is properly constructed and compacted.  Ensure components are properly shipped and placed.  Ensure joints are properly installed to acceptable tolerances.  Ensure proper fit and construction to acceptable dimension tolerances.  Maintain documentation of fabrication, certifications and placement.

B) CONCRETE BOX CULVERTS - SECTION 02646 General This item includes the materials, and construction of cast in place concrete box culverts. Precast box culverts are addressed in other specifications. Associated work may include construction of wingwalls, forming, shoring and backfilling. Buy America requirements apply to Federally funded projects. Cast in place box culverts are commonly used as buried drainage structures to convey water underneath the roadway. They are also used as pedestrian, wildlife and utility structures. Cast in

UTAH DEPARTMENT OF TRANSPORTATION

Page | 19

UDOT

Construction Inspection Guide

place systems have proven to be one of the most durable structure types if properly construction and can last for more than100 years. Constraints of cast in place culverts include the availability of ready mix suppliers, quality of construction in the field, and additional time to construct. Cast in place concrete box culverts consist of preparing a sub-base, placement of reinforcing steel, forming and placement of concrete. The Inspector is responsible to ensure that materials, construction and safety processes meet specifications. Box culverts are typically buried structures that require excavation. The Inspector should ensure that excavated slopes are laid back to meet OSHA standards with acceptable egress access points. The sub-grade needs to be prepared to the proper dimensions and compacted to tolerances. Materials such as reinforcing steel require certification and verification of proper placement in the field. Concrete requires approval of mix designs, proper placement and materials testing in the field. Backfill materials need to meet specifications and are to be compacted to acceptable tolerances. The Inspector should ensure that the culvert is installed to dimensions and specifications in the plan package. This includes proper depths, cover, and flow tolerances.

Submittal Requirements Prior to construction, the contractor shall submit the following for approval: 1. Project Schedule that included milestones and dates for the construction, traďŹ&#x192;c control, concrete placement and backfill. 2. Excavation safety plan. Page | 20

CHAPTER 6: STRUCTURES

CHAPTER 6 3. Certification of manufactured materials such as reinforcing steel. 4. Concrete Mix designs. 5. Certifications for bedding materials and backfill materials. 6. Shop drawings for any associated structural steel items such as inlet grates and frames. 7. Buy America Certification/Documentation.

Common Issues Document these common contractor issues: 1. Excavation does not meet OSHA safety standards. 2. Materials Certifications or mix designs are missing or do not meet specifications. 3. Reinforcing steel is not properly placed or tied. 4. Concrete is not properly placed or finished. 5. Concrete material testing does not meet specifications. 6. Bedding material is not adequately compacted or prepared. 7. Backfill materials do not meet specifications or is not adequately compacted. 8. Structure is not properly formed or shored. 9. Finish of concrete is substandard. 10. Structure is not constructed to proper dimensions or tolerances.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 21

UDOT

Construction Inspection Guide 02646: CONCRETE BOX CULVERTS

Pre-Inspection  Project schedule.  Shop drawings and design calculations signed and sealed by Utah licensed professional engineer.  Material certiﬁcations and mix designs.  Contractor has used a prequaliﬁed source for precast structures.  Excavation safety plan.  Reinforcing steel has been properly placed and tied.  Anchor bolts, fence post and incidental items have been installed.  Erection Plan is required prior to placement.  Buy America Documentation if applicable.

Field Documentation  Excavation meets safety standards.  Bedding material properly constructed.  Reinforcing steel has been properly placed and tied.  Forming and shoring meet requirements.  Concrete is properly placed and meets materials tests.  Backfill materials meet specifications and have been properly compacted.  Structure is built to acceptable dimensions and tolerances.  Maintain documentation of fabrication, certifications and placement.

Field Inspection  Site is excavated to the required depth and elevation.  Contractor has used suitable materials for backfill, depth of lift, optimum moisture and compaction. Refer to Chapter 3 of this guide.  Contractor has provided the test reports from the UDOT Materials Division for precast structures.  Compaction and fill requirements have been met. Backfill documentation per MS&TR Section 02056.

Page | 22

CHAPTER 6: STRUCTURES

CHAPTER 6

C) PRECAST NOISE RETAINING WALLS - SECTION 02861 General This item includes the materials, fabrication and placement for precast noise-retaining walls. These wall systems are typically pre-fabricated using reinforced concrete. Other walls systems such as Mechanically Stabilized Earth (MSE) walls are covered in other specifications. Associated work includes forming, false-work and shoring, placement of concrete, finishing, and curing. Precast retaining-noise walls are commonly used to provide a noise and/or visual barrier between traffic and surrounding communities. They can also be used on limited applications such as precast Post and Panel retaining walls. Precast retaining-noise walls consist of reinforced concrete posts and panels that are prefabricated and shipped to the project site for installation. Fabrication is typically completed by a pre-approved fabricator and inspected for approval by UDOT’s Central Materials Division prior to shipment. However, walls are also occasionally cast on site with the prior approval by UDOT’s Materials Division. UDOT’s central materials division is responsible for the quality control of precasting process including materials, forming, casting and curing of prestressed concrete structural components. As such, the Resident Engineer or staff should notify UDOT’s central materials and structures division of contractor schedule to fabricate precast walls systems. The Resident Engineer will receive “shop drawings” submitted for approval prior to fabrication. The Resident Engineer is responsible to forward these drawings to the designer of record and also notify UDOT’s central materials and bridge inspection staff. The central materials Inspector will verify the fabrication process including materials requirements for aggregates, concrete mix designs, reinforcing steel and aggregates. They will also verify the casting and curing processes. Once cured and approved, the precast components will be shipped with a label certifying the quality and approval. The field Inspector should verify this label is present prior to placement on the project site. Once the finished product leaves the precast yard, it becomes the responsibility of the field Inspector who is to ensure that the component is handled properly and not damaged. As posts and panels are placed in to final

UTAH DEPARTMENT OF TRANSPORTATION

Page | 23

UDOT

Construction Inspection Guide

position, the Inspector should verify that the contractors lifting practices are safe and adequate. Once in place, the Inspector should also verify that the contractor has properly braced or shored the component to prevent it from moving or falling. The Inspector should ensure that the posts and panels are installed to dimensions and specifications in the plan package. This includes proper depths of post embedment, concrete post grout placement, height, spacing and joint tolerances. Panels should be vertically plumb, and free of surface defects. In general, the fabricator is responsible for producing a quality precast product, and the contractor for the proper placement and construction of the component. The Inspector is responsible to ensure that processes have been followed for both fabrication and installation.

Submittal Requirements Prior to fabrication and installation, the contractor shall submit the following for approvalal: 1. Project Schedule that included milestones and dates for the fabrication, shipping and placement of precast concrete structural components. 2. Shop Drawings for approval of Precast components by the design Engineer with notification to UDOTâ&#x20AC;&#x2122;s Structures Division. 3. Notification to UDOTâ&#x20AC;&#x2122;s Central Materials Lab and Resident Engineer of schedule to form and cast the precast components. 4. Certification of materials and fabrication process to be approved by UDOT Central Materials Division prior to fabrication. 5. Erection Plan. 6. Buy America Certification/ Documentation. Page | 24

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues Document these common contractor issues: 1. Shop Drawings are missing or delayed. 2. Approvals, certifications, and inspection not coordinated with Central Materials, lead designer or Structures Division. 3. Finish of concrete is substandard. 4. Finished product is damaged during shipment or placement. 5. Structural component is not lifted or placed in a safe manner. 6. Contractor fails to shore or brace components after placement. 7. Post are not imbedded to proper depth or grouted with concrete as specified. 8. Panels are not installed to acceptable dimensions or fit. 02861: PRECAST RETAINING NOISE WALL

Field Documentation  Central Materials to certify fabrication and approval of component.  Inspector to document and verify fabrication certification.  Ensure components are properly shipped and placed.  Ensure components are properly braced after placement.  Ensure proper fit and construction to acceptable dimension tolerances.  Maintain documentation of fabrication, certifications and placement.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 25

UDOT

Construction Inspection Guide

D) OVERHEAD SIGN VMS STRUCTURE - SECTION 02893 General This item includes specifications for the materials, fabrication and installation of structural steel materials used in the construction of overhead sign and VMS signs. Structural steel components are typically used to construct the frame of these structures and reinforced concrete is used to construct the foundations. Structural Steel and Reinforced Concrete specifications should also be used with these structures. Additional “Buy America” requirements apply for Federally funded projects. Poor material or construction quality has the potential for catastrophic failure of these structures. The Resident Engineer and Inspector are responsible to ensure that the process for producing the materials and fabricating the final products follow specifications. In addition, they are responsible to ensure that the fabricated products are properly placed and constructed in the field.

Certifications Structural steel is available in common and custom shapes, grades and dimensions from both domestic and foreign manufacturers. Steel is manufactured by a steel mill (manufacturer) from raw materials into common shapes and sizes. A steel supplier or fabricator typically resells, reshapes or modifies the steel into the final product shape and configuration. The steel production mill and fabricator may or may not be the same company and the Inspector is responsible for certifications for both the materials and fabrication. Certified Mill Test Reports (MTR) must be submitted for all structural steel materials, including those manufactured outside the United States. Additional “Buy America” requirements apply for Federally funded projects. The fabricator of structural items must be AISC – Major Steel Bridge (CBR) certified if components are used on a bridge structure. UDOT’s Central Materials Division oversees the quality process for the manufacturing and fabrication of structural steel items. The Resident Engineer and Inspector are responsible to notify them of structural steel items used on the project. Page | 26

CHAPTER 6: STRUCTURES

CHAPTER 6 Reinforced concrete foundations require the approval of aggregates, mix designs, reinforcing steel and materials testing of the concrete.

Drawings The fabricator and contractor are required to submit detailed shop and erection drawings prior to fabrication and erection. After approval, the shop drawings become a part of the project plans and are used in lieu of the general plans insofar as steel details are concerned. During erection, make sure all members are placed in their proper position in the structure by checking match marks or identification marks on the members with the location shown on the erection drawing. When checking the shop drawing, the goal is to end up with error free drawings. The drawings are checked and approved by the UDOT Structures Division. When the shop drawings are approved they are not guaranteed to be free from error nor are the Fabricator and Contractor relieved from the responsibility to furnish material that meets the requirements of the Plans and Specifications. Although the shop drawings are checked and approved, be alert to catch fabrication discrepancies.

Shop Inspection The Contractor will be required to provide at least two weekâ&#x20AC;&#x2122;s notice before the beginning of shop work so that shop inspections can be scheduled. Such inspection is normally provided by the Central Materials and/or Structures Division. Nevertheless, perform a steel visual inspection as it is received on the project, before unloading. The inspection requirements for the shop inspection are provided in the AASHTO Construction Manual of Highway Bridges and Incidental Structures. Unloading, Handling and Storing Upon delivery of the steel it is inspected for signs of damage and any such damage is documented and reported to the Contractor. The unloading of the steel is accomplished by means of equipment and methods which will not damage the members. The steel is moved by use of slings and wood blocks to prevent damage to the flanges. Steel members are never to be dropped. Steel is stored in a well-drained area which is not in danger of being flooded. All beams and girders are placed in an upright position, on wooden blocks. Blocking is provided that will keep all members oďŹ&#x20AC; the ground and clear of grass, brush or other material. Long members are supported in a manner that will prevent damage from deflection. The members are also handled and transported in an upright position. They are braced to prevent overturning. A girder erection plan stamped by a licensed Structural Engineer is required from the contractor and supplier prior to installing steel girders.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 27

UDOT

Construction Inspection Guide

Erection and Construction The structural steel components are to be erected and placed into final position by an experienced contractor. The Inspector should ensure that girders and other components properly fit and are placed into the position as shown on the plans. Field cutting, welding and bending during erection should not be allowed without the approval of the Designer or a Structural Engineer due to the potential to weaken the capacity of the structure. Placement often occurs over several days, and the Inspector should ensure that the contractor has taken precaution to brace and restrain the components from moving or falling.

Submittal Requirements The contractor shall submit the following for approval: 1. Project Schedule with milestones for fabrication. 2. Certifications of nut proof load tests. 3. Buy America certification (if applicable) 4. Material certifications, and mill test reports (MTR). 5. Fabricator certification as AISC-CBR if a bridge structure. 6. Shop Drawings. 7. Erection Plans for bridges stamped by a Structural Engineer.

Common Issues The Inspector and Resident Engineer are responsible to document common contractor errors and notify a Structural Engineer if any of the following are observed: 1. Shop Drawings are delayed or missing or not stamped by a Structural Engineer. 2. Missing approvals, certifications, and inspections that have not been coordinated with Central Materials or Structures Divisions. 3. Damage of steel during shipment or placement. 4. Improper welding, cutting, bending or modification in field 5. Improper fit or alignment. 6. Excessive deflection, movement or instability. 7. Non approved connection hardware. 8. Bolts under-tightened or over-tightened at splice plates or diaphragms. Page | 28

CHAPTER 6: STRUCTURES

CHAPTER 6 02893: OVERHEAD SIGN VMS STRUCTURES

Pre-Inspection  Contractor to Submit Project Schedule including structural steel items.  Contractor to Submit Shop Drawings for approval.  Contractor to submit Nut proof load tests.  Contractor/Supplier to submit Mill Certiﬁcations.  Contractor/Suppler to submit AISC-CBR certiﬁcations if a bridge.  Contractor to submit erection plan for bridges stamped by SE.

Field Documentation & Inspection  Central Materials to certify and approve fabrication.  Inspector to document and verify fabrication certiﬁcation.  Ensure components are properly shipped and placed.  Ensure components are properly braced after placement.  Maintain documentation of fabrication, certiﬁcations and placement.  Contact Structural Engineer for any abnormal issues.  Ensure all bolts have been adequately tightened.

E) REINFORCING STEEL

AND

WELDED WIRE FABRIC - SECTION 03211

General This item includes the material and placement for reinforcing steel and welded wire fabric used in reinforced concrete structures. In general, reinforcing steel or welded wire fabric shall conform to the proper grade, size, and dimensions as specified in the plan package. The materials must meet certification requirements. Most reinforcing steel used on highway projects is coated with epoxy or galvanized to prevent corrosion. The Inspector should ensure that the contractor has placed the reinforcing steel and welded wire fabric to the proper location, dimensions and geometry as specified in the plan package, including cover, spice lengths and securing with tie wire and support chairs. Buy America requirements apply to Federally funded projects.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 29

UDOT

Construction Inspection Guide

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Material Certifications for reinforcing steel and welded wire fabric. 2. Shipping invoices with manufacturer contact information, lot numbers, rebar bar call outs, size, and quantities. 3. Plan for storage of materials prior to placement.

Common Issues Document these common contractor issues: 1. Material lacks proper certifications and documentation. Material damaged or not stored properly. 2. Material improperly placed and does not meet plans or specifications. Protective coating is damagĞd. 03211: REINFORCING STEEL AND WELDED WIRE FABRIC

Pre-Inspection  Submit material certiﬁcations and source of manufacturing.  Submit shipping invoices.  Buy America documentation if applicable.

Field Documentation         

Page | 30

Observe that reinforcing materials have proper ﬁeld tags to identify. Observe that reinforcing materials are properly stored. Ensure that protective coatings are not damaged. Observe that reinforcing materials have been properly placed to the proper location including tensile and compressive faces. Ensure that reinforcing materials have proper cover. Ensure that reinforcing materials have proper splice length. Ensure that reinforcing steel is properly tied and secured so as not to move or displace during concrete placement. Ensure that exposed reinforcing ends are covered and do not create a safety hazard. Maintain documentation for reinforcing materials including certiﬁcations, shipping invoices and approval notices.

CHAPTER 6: STRUCTURES

CHAPTER 6

F) STRUCTURAL CONCRETE - SECTION 03310 General This item includes the material and placement for structural concrete for cast in place applications. Associated work includes forming, false-work and shoring, placement of concrete, finishing, and curing. In general, the contractor shall provide a mix design that meets the specific requirements of the structure plans and place the concrete in a manner that provides the desired strength, finish and quality. The Inspector is responsible to ensure that the material and placement are satisfactory and documenting the process. Prior to placement of structural concrete, the Inspector shall inspect the reinforcing steel, forming and mix designs and give a notice to proceed for concrete placement. During placement, the Inspector shall perform material tests or coordinate with the materials testing personnel for items such as air entrainment, slump and compressive strength. The Inspector is also responsible to ensure that workmanship meets the plan package including the use of equipment such as concrete pumps and vibrators and finishing of exposed surfaces.

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Concrete Mix Design for approval by the Engineer. 2. Prior notification of schedule to place concrete and notification to Inspectors and materials testing personnel. 3. The Engineer must give approval and notice to proceed with concrete placement prior to performing work.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 31

UDOT

Construction Inspection Guide

Common Issues Document these common contractor issues: 1. Concrete materials do not have approved mix design. 2. Reinforcing steel is not properly placed. 3. Forming and shoring are not properly placed. 4. Improper use of equipment such as concrete pumps, tremmies and vibrators. 5. Substandard workmanship and finishing. 6. Concrete does not meet air, slump or strength requirements. 7. Concrete does not meet mix times or haul time requirements. 8. Excessive cold, heat or weather conditions. 9. Segregation of aggregate from mix during placement. 10. Finished grade aﬀected by dead load deflections of concrete weight.

03310: STRUCTURAL CONCRETE

Pre-Inspection  Contractor to Submit concrete mix design for approval.  Contractor to give prior notice of schedule for inspection & material testing.  Inspector to ensure forming and shoring in place.  Inspector to ensure reinforcement in proper placement.  Ensure that contractor has compensated for dead load deﬂections.  Contractor has adequate equipment (tremmies, pumps, etc.).  Ensure that anchor bolts, fence posts and other details are in place.

Field Documentation  Ensure concrete meets air entrainment and slump requirements.  Ensure that pumping equipment is properly used and from an approved source.  Ensure that workmanship meets requirements of plan package.  Ensure that reinforcing steel does not move during placement.  Maintain documentation for reinforcing materials including certiﬁcations, shipping invoices and approval notices.  Document location and time of placement and construction joints.

Page | 32

CHAPTER 6: STRUCTURES

CHAPTER 6

G) CONCRETE CURING - SECTION 03390 General This item includes the specifications for the curing of concrete. Requirements specific to concrete structures are included within this specification. In general, the majority of structural concrete is performed on the job site using cast construction methods. Concrete cures in part by a chemical reaction where the cement ingredients react with the hydrogen molecules that are present in the water. If the water is allowed to excessively evaporate, the concrete quality can be reduced. As a result, concrete curing compounds are used to seal the moisture in during the curing process for all cast in place concrete structures. Bridge decks and approach slabs require the additional use of a fabric or other material that retains moisture. Unless specified otherwise, curing compounds are to be applied within 20 minutes of placement of the concrete at an application rate not to exceed 100ft /gallon. In some cases, precast concrete may be used and have specific requirements for curing such as early strength, or controlled environment conditions such as wet curing, steam curing, and temperature controls. The quality inspection for precast structural components is typically performed by UDOTâ&#x20AC;&#x2122;s Central Materials Division. The field Inspector is responsible to notify the Central Materials Division of upcoming precast elements for their project. Curing Compounds and curing fabrics are available from numerous suppliers and manufacturers. The contractor is responsible to provide the Engineer with a process to ensure

UTAH DEPARTMENT OF TRANSPORTATION

Page | 33

UDOT

Construction Inspection Guide

that moisture levels are maintained during the curing of structural concrete. The contractor is responsible to select appropriate materials that meet UDOT specifications. The contractor must submit material information including the manufacturer, material certifications, product data, specifications, and recommended instructions. The Resident Engineer and field Inspector are responsible to approve material submittal prior to use. In addition, they need to observe that curing compounds are adequately applied in a timely manner.

Submittal Requirements Prior to use, the contractor shall submit the following for approval: 1. Curing Compound a. Material Supplier Information b. Product Data c. Material Certification d. MSDS sheets 2. Curing Fabric (decks) a. Material Supplier Information b. Product Data c. Material Certification

Common Issues Document these common contractor issues: 1. Material Certifications are missing. 2. Missing product installation instructions. 3. Application rates are not maintained. 4. Improper storage of materials. 5. Wet conditions are not maintained for curing fabrics. 6. Cold Weather Concrete. Page | 34

CHAPTER 6: STRUCTURES

CHAPTER 6 03390: CONCRETE CURING

Pre-Inspection  Contractor to Submit manufactures contact information, product data, material certiﬁcations, MSDS Sheets, storage requirements, and installation instructions for curing compounds and fabrics.  Central Materials Division has been notiﬁed of any precast elements on the project.

Field Documentation  Verification and documentation of material certifications.  Inspector to document and verify storage and installation.  Ensure components are properly placed and maintained during cure.  Maintain documentation of fabrication, certifications and placement.

H) PENETRATING CONCRETE SEALER - SECTION 03392 General This item includes materials used as a preventive treatment to seal water and deicing salts from structural concrete surfaces. The contractor is responsible to provide acceptable materials and apply them in a manner that meets specifications for the project. The Inspector is responsible to verify material certifications, observe acceptable application and document the process.

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Manufacturer’s product data, material certifications, recommendations for storage and installation. 2. Certifications of minimum friction numbers when used on traveled surfaces.

Common Issues Document these common contractor issues: 1. Missing product data and installation instructions. 2. Improper storage or handling. 3. Application rates do not meet specifications. 4. Overspray during application. 5. Storage and handling.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 35

UDOT

Construction Inspection Guide

03392: PENETRATING CONCRETE SEALER

Pre-Inspection  Contractor to submit manufacturer’s product data, material certiﬁcations, speciﬁcations and instructions for use and storage.  Manufacturer and Contractor to submit Materials Safety Data Sheets (MSDS) with instructions for handling, safety and emergencies.  Inspector to coordinate approvals with UDOT Central Materials Division.  Ensure documentation of material submittals.

Field Documentation  Inspector to document and verify materials certification.  Ensure components are properly stored.  Materials are safely and properly mixed.  Materials are applied at specified coverage.  Proper disposal of waste materials.  Documentation of certifications, and application in inspection diaries.

I) PRESTRESSED CONCRETE - SECTION 03412 General This item includes the materials and placement for structural concrete that includes the use of pre-stressing strands (wire cables) which are used to add strength and load capacity for the structural section. Associated work includes forming, false-work and shoring, placement of concrete, finishing, and curing. Prestressing strands are commonly used for concrete bridge girders, and occasionally used for other structural members such as precast deck panels or pier caps. Prestressed concrete is almost always completed by a UDOT approved precast concrete fabricator. The process involves the tensioning (prestressing) of the strands (wire cables) before the concrete is placed. Once the concrete has been placed and cured to a satisfactory strength, the strand ends are cut. Page | 36

CHAPTER 6: STRUCTURES

CHAPTER 6

UDOT’s central materials division is responsible for the quality control of the precasting process including materials, forming, casting and curing of prestressed concrete structural components. As such, the resident Engineer or staﬀ should notify UDOT’s central materials and structures division of contractor schedule to fabricate prestressed elements. The Resident Engineer will receive “shop drawings” submitted for approval prior to fabrication. The Resident Engineer is responsible to forward these drawings to the designer of record and also notify UDOT’s central materials and bridge inspection staﬀ. The central materials Inspector will verify the fabrication process including materials requirements for aggregates, concrete mix designs, reinforcing steel and prestressing strands. They will also verify the casting and curing processes. Once cured and approved, the precast components will be shipped with a label certifying the quality and approval. The field Inspector should verify this label is present prior to placement on the project site. Once the finished product leaves the precast yard, it becomes the responsibility of the field Inspector who is to ensure that the component is handled properly and not damaged. As girders or other component are placed in to final position, the Inspector should verify that the contractors lifting practices are safe and adequate. Once placed, the Inspector should also verify that the contractor has properly braced or shored the component to prevent it from moving or falling.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 37

UDOT

Construction Inspection Guide

The design of prestressed structural components takes into account added weights from dead loads such as decking and parapets. If a girder or other component is allowed to be stored for too long of a time before placement of these dead loads, there is a potential for the component to “bow” or lose shape. The Inspector should ensure that the girders are installed in a reasonable period of time after fabrication. Prestressed girders typically are installed in the field with bracing (diaphragms) between the girders to provide lateral stability. The Inspector should ensure that all diaphragms have been properly installed or constructed before opening to traﬃc. Diaphragms can be constructed in the field using reinforced cast-in-place concrete or installation of prefabricated steel diaphragms. The Inspector needs to ensure that reinforcing steel and concrete is properly installed. Proper installation of connection bolts and welding of steel diaphragms needs to be verified in the field. In general, the fabricator is responsible for producing a quality precast product, and the contractor for the proper placement and construction of the component. The Inspector is responsible to ensure that processes have been followed for both fabrication and installation.

Submittal Requirements Prior to fabrication and installation, the contractor shall submit the following for approvalal: 1. Project Schedule that included milestones and dates for the fabrication, shipping and placement of prestressed concrete structural components. 2. Shop Drawings for approval of Prestressed and Precast components by the design Engineer with notification to UDOT’s Structures Division. 3. Notification to UDOT’s Central Materials Lab and Resident Engineer of schedule to form and cast the prestressed components. 4. Certification of materials and fabrication process to be approved by UDOT Central Materials Division prior to fabrication. 5. Erection Plan stamped by a Professional Structural Engineer for bridge projects.

Page | 38

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues Document these common contractor issues: 1. Shop Drawings are missing or delayed. 2. Approvals, certifications, and inspection not coordinated with Central Materials, lead designer or Structures Division. 3. Finish of concrete is substandard. 4. Finished product is damaged during shipment or placement. 5. Structural component is not lifted or placed in a safe manner. 6. Contractor fails to shore or brace components after placement. 7. Finished product is stored too long before adding deck or other dead loads resulting in excessive camber. 8. Damage during shipment or placement. 03412: PRESTRESSED CONCRETE

Pre-Inspection  Contractor to submit project schedule that includes prestressed items.  Contractor to Submit Shop Drawings for approval.  Inspector to coordinate inspection with UDOT Lead Designer, Central Materials and Structures Division.  Central Materials Inspector to ensure materials certiﬁcations, mix designs, forming, placement, curing and overall fabrication process.  Fabricator to ensure that incidental items such as parapet ties, fence post, anchor bolts and other details are included prior to casting concrete.  Girder Erection Plan stamped by a Structural Engineer is required prior to placement of girders.

Field Documentation  Central Materials to certify fabrication and approval of component.  Inspector to document and verify fabrication certiﬁcation.  Ensure components are properly shipped and placed.  Ensure components are properly braced after placement.  Maintain documentation of fabrication, certiﬁcations and placement.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 39

UDOT

Construction Inspection Guide

J) STRUCTURAL STEEL - SECTION 05120 General This item includes specifications for the materials, fabrication and installation of structural steel materials used in the construction of bridges and other transportation structures. Common structural steel components include; steel girders, sign structures, girder diaphragms, and connection bolts and hardware. Associated items include nuts, bolts, washers and other miscellaneous components. Additional “Buy America” requirements apply for Federally funded projects. Steel components used on structures typically are designed to carry loads and support the weight of the bridge and traﬃc. Poor material or construction quality has the potential for catastrophic failure of the structure and loss of life. The Resident Engineer and Inspector are responsible to ensure that the process for producing the materials and fabricating the final products follow specifications. In addition, they are responsible to ensure that the fabricated products are properly placed and constructed in the field.

CHAPTER 6: STRUCTURES

CHAPTER 6 outside the United States. Additional “Buy America” requirements also apply for Federally funded projects. The fabricator of structural items must be AISC – Major Steel Bridge (CBR) certified if components are used on a bridge structure. UDOT’s Central Materials Division oversees the quality process for the manufacturing and fabrication of structural steel items. The Resident Engineer and Inspector are responsible to notify them of structural steel items used on the project.

Shop Inspection Advise the Contractor that it will be necessary to have at least two week’s notice before the beginning of shop work so that shop inspections can be scheduled. Such inspection is normally provided by the Central Materials and/or Structures Division. Provide a visual inspection as it is received on the project, before unloading. The inspection requirements for the shop inspection are provided in the AASHTO Construction Manual of Highway Bridges and Incidental Structures. Unloading, Handling and Storing Upon delivery of the steel it is inspected for signs of damage and any such damage is documented and reported to the Contractor. The unloading of the steel is accomplished by means of equipment and methods which will not damage the members. The steel is moved by use of slings and wood blocks to prevent damage to the flanges. Steel members are never to be dropped. Steel is stored in a well drained area which is not in danger of being flooded. All beams and girders are placed in an upright position, on wooden blocks. Blocking is provided that will keep all members oﬀ the ground and clear of grass, brush or other

UTAH DEPARTMENT OF TRANSPORTATION

Page | 41

UDOT

Construction Inspection Guide

material. Long members are supported in a manner that will prevent injury from deflection. The members are also handled and transported in an upright position. They are braced to prevent overturning. A girder erection plan stamped by a licensed Structural Engineer is required from the contractor and supplier prior to installing steel girders.

Erection and Construction The structural steel components are to be erected and placed into final position by an experienced contractor. The Inspector should ensure that girders and other components properly fit and are placed into the position as shown on the plans. Field cutting, welding and bending during erection should not be allowed without the approval of the designer or a Structural Engineer due to the potential to weaken the capacity of the structure. Placement often occurs over several days, and the Inspector should ensure that the contractor has taken precaution to brace and restrain the components from moving or falling.

Submittal Requirements The contractor shall submit the following for approval: 1. Project Schedule with milestones for fabrication. 2. Certifications of nut proof load tests. 3. Buy America certification (if applicable). 4. Material certifications, and mill test reports (MTR). 5. Fabricator certification as AISC-CBR if a bridge structure. 6. Shop Drawings. 7. Erection Plans for bridges stamped by a Structural Engineer.

CHAPTER 6: STRUCTURES

CHAPTER 6 4. Improper welding, cutting, bending or modification in field 5. Improper fit or alignment. 6. Excessive deflection, movement or instability. 7. Non-approved connection hardware. 8. Bolts under-tightened or over-tightened at splice plates or diaphragms. 05120: STRUCTURAL STEEL

K) BEARINGS - SECTION 05822 General This item includes the materials and placement for bearings used in conjunction with bridge girders. Bearings are required to help distribute the weight of the beams and traﬃc to the bridge foundation. Before erection of girders is started, the centerline of bearings is laid out on abutments and pedestals. Bearing areas are inspected to ensure that a smooth surface is provided at the correct elevation. If the concrete surface that will be in contact with the bearing pad is rough or irregular, it is ground to provide full and uniform bearing. If a bearing area is low with respect to other areas on the unit or in relation other units of the structure, shims of the same size as the masonry plate, and of the required thickness, are ordered with the approval of

UTAH DEPARTMENT OF TRANSPORTATION

Page | 43

UDOT

Construction Inspection Guide

the Structures Division. The most common bearing materials are preformed elastomeric pads or steel. Buy America requirements apply to Federally funded projects.

Bearing Pads Pre-formed fabric or plastic bearing pads are required to conform to AASHTO Specification M-108 for Highway Bridges. Such pads may be used without testing provided a certification has been received stating that the material proposed for use complies with the Specifications. If no certificate has been received, a sample is submitted and tested by the Materials Division before use. Steel bearing units must meet structural steel specifications and require material certifications.

Installation Bearing surfaces need to be free of debris. Contact surfaces of beams need to be free of paint or lacquer. Elastomeric bearing pads are placed under the girders to dimensions shown in the plans. Care should be taken as girders are set as to not tear or damage the bearing pads. Styrofoam is placed in front of the bearing pads for abutments that will have cast in place end diaphragms. Steel bearing systems often include anchor plates and connection bolts. Care should be taken to ensure that anchor bolts are properly installed in the correct location prior to setting girders. Welding or cutting of any structural steel should not be allowed unless specified on the plans or Page | 44

CHAPTER 6: STRUCTURES

CHAPTER 6 approved by a Structural Engineer. Older style rocker bearing units require “setting” the angle to the ambient temperature when installed.

Submittal Requirements Prior to fabrication and installation, the contractor shall submit the following for approvalal: 1. Shop Drawings for approval per section 05120.

Common Issues Document these common contractor issues: 1. Shop Drawings are delayed. 2. Approvals, certifications, and inspection not coordinated with Central Materials. 3. Finish of abutment concrete is substandard. 05822: BEARINGS

Pre-Inspection  Contractor to Submit Shop Drawings for approval.  Inspector to coordinate inspection with UDOT Central Materials and Structures Division.  Inspector to ensure proper placement.

L) PAINTING STRUCTURAL STEEL - SECTION 09972 General This item includes specifications for the materials and application of painting systems for structural steel. Structural steel painting is performed primarily to extend the life of a structure by slowing the corrosion process. This specification is for new painting systems. Requirements for top-coating or repainting of structural steel are covered in other specifications. The life of a paint system and its ability to slow corrosion are determined by the quality of the materials and how well they are applied. The Inspector is responsible to ensure that these

UTAH DEPARTMENT OF TRANSPORTATION

Page | 45

UDOT

Construction Inspection Guide

two conditions are met. In addition, the Inspector needs to ensure that the paint systems do not adversely aﬀect the environment, or worker safety.

Painting Plan The contractor is required to submit for approval a comprehensive painting quality plan that includes the following: • Painting Protection plan that includes environmental protection plans, and overspray protection plans. • Safety Plan for worker exposure and fall protection. • Source, gradation and procedures for sandblasting and surface preparation. Type and source of solvents and thinning agents. • Material information and data for each component of the 3 part paint system. This shall include film thickness requirements, Product Safety Data, thinning requirements, temperature requirements, surface profile (roughness) requirements, mixing instructions and equipment recommendations.

CHAPTER 6: STRUCTURES

CHAPTER 6 and approval to UDOTâ&#x20AC;&#x2122;s Central Materials Paint lab. UDOT will test paint samples from each batch or lot prior to use and will reject or approve paints in comparison to the standard.

Painter and Sandblaster Qualifications The painter and sandblaster are required to be certified prior to the contract award by the Society of Protective Coatings (SSPC). DiďŹ&#x20AC;erent certifications are required for painters and sandblasters and for field work and shop work.

Submittal Requirements The contractor shall submit the following for approval: 1. Project Schedule with milestones for painting operations. 2. Paint Plan including: Environmental protection plan, safety plan, materials source and data, sandblasting operations, test samples and a quality plan. 3. Approval of paint samples by UDOT Central Materials. 4. Certification of Painters and Sandblasters.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 47

UDOT

Construction Inspection Guide

4. Contractor does not adequately protect surrounding environment or traﬃc from overspray. 5. Surface is not adequately cleaned or does not have an eﬀective surface profile for the paint system to bond to. 6. Paint is applied at improper application rates, thicknesses or lacks uniformity. 7. Too much time between prime, intermediate and top coats. 09972: PAINTING STRUCTURAL STEEL

Pre-Inspection  Submittal of Painting Plan including requirements of 09972.  Painter and Sandblaster qualiﬁcations.  Material Safety Data Sheets.  Test samples submitted to Central Materials Paint lab.

Field Documentation & Inspection  Field pre-qualify painters using test area.  Verify enforcement of safety plan, including scaffolding, fall protection and work exposure to hazardous materials.  Ensure paint and other materials are properly shipped and stored.  Ensure MSDS sheets and product information is readily available.  Ensure surfaces are clean and prepared to acceptable proﬁle and free of debris and dust prior to paint coat.  Measure application rates, thicknesses and processes for applying paint.

Page | 48

CHAPTER 6: STRUCTURES

CHAPTER 6

6.5 BRIDGE DECKS, APPROACHES AND JOINTS

A) BRIDGE CONCRETE GRINDING - SECTION 02982 General This item includes procedures for grinding new concrete deck and approach slab systems. Grinding of the concrete deck and approach slab surfaces is typically done to achieve a desired profile and ride of precast concrete bridge deck systems. Grinding is also performed to remove polymer overlay systems, or to remove deteriorated concrete. The Inspector should visually inspect the equipment and operations to ensure that the grinding operations do not cause damage to reinforcing steel, steel grating or expansion joints. Grinding operations often can create dust, noise, and waste water which have potential for safety hazards to workers and drivers. The Inspector should also inspect the overall safety of the operations and ensure that the contractor has obtained necessary permits.

Submittal Requirements Prior to construction, the contractor shall submit the following for approval: 1. Noise and other related permits.

Common Issues Document these common contractor issues: 1. Equipment breakdowns. 2. Damage to reinforcement, joints and grating. 3. Cross slope drainage not achieved. 4. Grinding surface not longitudinal and smooth. 5. Missing noise permits.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 49

UDOT

Construction Inspection Guide 02982: BRIDGE CONCRETE GRINDING

Pre-Inspection  Verify equipment meets the job size and complexity.  Discuss common issues with contractor prior to grinding operations.  Allow cure time for cast in place deck joints.  Deﬁne smoothness requirements with contractor before grinding.  Obtain necessary noise and waste water permits.

Field Documentation  Inspect and Verify smoothness.  Inspect and Verify drainage.  Ensure vacuuming or collection of waste water.  Inspect and verify grinding depth.  Inspect and verify that no damage has occurred to deck joints, catch basins or surface.  Document labor and equipment used.

B) JOINT CLOSURE - SECTION 03311 General Prior to the 1980’s the bridge deck joints were used more frequently than current design practices. Bridge deck joints typically leak allowing water and deicing salts to drain onto the piers and columns below increasing the rate of deterioration for the bridge. As a result, bridge deck joints are eliminated (closed) where possible on existing bridges.

Inspection A bridge deck joint closure consists of removing the existing joint system, installing reinforcing steel and casting concrete to fill the joint area (closure). This specification describes materials and processes for removing and closing deck joint systems. Custom plans are typically prepared that are specific to the individual bridge. The Inspector should take extra eﬀort to understand the bridge plans and ask for clarification from the designer if needed. The Inspector should ensure that the removal operations do not cause damage to the surrounding concrete and structure. Jack hammers and other equipment should be an appropriate size as to not cause damage. Placement of new reinforcing is typically doweled spliced or mechanically coupled to the adjacent deck reinforcement. The Inspector should verify that the placement of Page | 50

CHAPTER 6: STRUCTURES

CHAPTER 6 reinforcing steel matches what is specified in the plans. Material certifications are required for the reinforcing steel and mix designs for the concrete.

Submittal Requirements 1. Prior to removal and closure, the contractor shall submit the following for approval: 2. Removal Plan with list of jack hammers and other equipment to be used. Material Certifications for reinforcing steel. 3. Mix designs for concrete.

Common Issues The Inspector should watch for these common issues: 1. Removal process damages surrounding concrete. Sawcutting is too deep, jackhammers are too heavy, etc. 2. Material certifications are delayed, or concrete mix designs are not approved. 3. Deterioration to surrounding concrete is more than expected. 4. Ride of finished concrete is not smooth. 03311: JOINT CLOSURE

Pre-Inspection  Approved equipment for removal of existing joint system.  Approved Concrete Mix Design.  Certiﬁcations for materials including reinforcing steel.  Buy America documentation if applicable.

Field Documentation  Saw-cut to proper depth.  Jack hammering and removal process does not damage surrounding concrete or structure.  New reinforcing steel is properly placed and protective coatings are touched up if damaged.  Concrete is properly formed, placed and cured.  Document temperature and placement for closure operations.  Field test concrete for air entrainment and slump.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 51

UDOT

Construction Inspection Guide

C) PRECAST CONCRETE DECK PANELS - SECTION 03339 General Historically, most bridge decks were constructed with cast in place concrete. However, in recent years the use of precast concrete deck panels has dramatically increased. Precast deck panels are commonly used to accelerate construction schedules, are used where ready mix materials are not available, or where the design wants a higher level of control in the curing process. Precast deck panels are used on both new construction and deck replacement projects. They oďŹ&#x20AC;er tremendous benefits such as a higher level of quality control during fabrication, winter weather construction, remote construction and rapid construction. However, they also pose additional complexities such as lifting, and fit of the panels. Precast deck panels are also commonly post tensioned with wire cables after placement to secure and tie the panels together. A primary role of the Inspector for precast deck panels is the coordination and communication of the fabrication and construction processes with other groups. Precast deck panels are a specialty structural item, and the Inspector needs to coordinate the fabrication, construction, inspection and approval of these systems with the designer, UDOTâ&#x20AC;&#x2122;s Structures Division, and UDOT Central Materials Division prior to beginning fabrication or construction.

Page | 52

CHAPTER 6: STRUCTURES

CHAPTER 6

Submittal Requirements Prior to fabrication, the contractor shall submit the following for approval: 1. Project Schedule with details for precast deck panels. 2. Shop Drawings from the precast fabricator for approval. 3. Construction Methods Plan. 4. Erection Plan. 5. Materials Certifications, including grout materials.

Common Issues Document these common contractor issues: 1. Certifications and Submittals not on time. 2. Lack of notification to UDOT Structures and Materials 3. Inadequate Survey and Fit of Panels. 4. Grouting of camber strip and block outs. 03339: PRECAST CONCRETE DECK PANELS

Pre-Inspection  Contractor to Submit Schedule with details for deck panel fabrication and construction.  Notiﬁcation to UDOT Structures and Materials Divisions.  Shop drawings submitted for approval.  Inspector to verify fabrication has been approved by UDOT Materials and Structures prior to shipment or construction.  Ensure Construction Methods Plan has been submitted and approved.  Ensure Construction Erection Plan has been submitted and approved.  Material Certiﬁcations have been submitted and approved.  Hold pre-construction -erection meeting.

Field Documentation  Inspect and document deck removal process (if required) to ensure no damage to girders and other structural components.  Inspect and document installation of panels including ﬁt, time, labor and equipment used. Ensure panels are safety handled and lifted into place within tolerances.  Ensure post-tensioning (if required) meets plans and speciﬁcations.  Ensure grouting of camber strip and anchor block outs have been properly grouted.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 53

UDOT

Construction Inspection Guide

D) THIN BONDED CONCRETE OVERLAY - SECTION 03372 General This item includes procedures for overlaying concrete bridge decks with a thin polymer material and wearing surface aggregate. Thin bonded overlays are typically placed as a preventive treatment to seal water and deicing salts from the deck. They are also occasionally placed to improve safety by increasing friction values.

Inspection Thin bonded overlays must be applied to a clean, dry deck surface. Without this critical step, the polymers are susceptible to de-bonding from the deck surface. The first step of the polymer overlay system is to clean the deck using a steel shot blasting. Steel shot is used because it does not leave a dust film behind. The steel shot is collected using magnets and recycled. Sand blasting is allowed only in areas where steel shot equipment canâ&#x20AC;&#x2122;t reach such as along the parapets. The Inspector should visually inspect the shot blasting operation including the equipment used to make sure the surface has been properly cleaned of any residues, sealing components, greases, oils, etc. Any potholes or defects in the deck surface should be repaired prior to the shot blasting operation. Once clean, the polymer resins can be mixed and applied. Polymer overlays come in two components that are liquids. The components are mixed by proportions specified by the manufacturer. Once blended, a chemical reaction starts, and the resin typically will start to gel within 15 minutes or less. It is critical to apply the mixed resin quickly to the deck surface before it starts to harden. Also, these polymers generate heat. The mixed resins should not be left to harden in a container as they pose a risk of explosion and injury if the heat canâ&#x20AC;&#x2122;t escape. The mixed resins should be applied to the deck surface within 5 minutes or less of mixing. The Inspector should visually inspect the blending, mixing and application of the resins. Consideration should be given to mixing proportions, mixing equipment, mix times, and time to application. Once the resins have been applied to the deck surface, they are covered with an aggregate wearing surface. The aggregate is typically basalt or other high wear rock material. The aggregate is spread (broadcast) into the wet resins before they harden. Page | 54

CHAPTER 6: STRUCTURES

CHAPTER 6 The Inspector should ensure that the aggregates adequately cover the wet resins before it hardens. Typically, two coats of resin and aggregate are applied. Excess aggregates are swept oﬀ before the deck is open to traﬃc.

Submittal Requirements The following items are required for submittal: 1. Manufacturer’s product data 2. Recommended installation instructions.

Common Issues The following are common issues with thin bonded polymer overlays: 1. Existing deck defects are not properly repaired. 2. Shot blasting equipment breaks down. 3. Deck surface is not adequately cleaned, especially of curing compounds on new decks. 4. The deck surface is not dry. 5. Resins are improperly mixed by proportion or quickly dispersed. 6. Aggregates do not adequately cover the resin before it hardens. 7. Contractor does not clean up excess aggregates. 03372: THIN BONDED CONCRETE OVERLAY

Pre-Inspection  Verify equipment meets the job size and complexity.  Discuss common issues with contractor prior to mixing and application.  Verify deck surface is clean and dry.  Verify material lot numbers and data.

Field Documentation  Inspect and verify shot blasting operations.  Inspect and Verify deck is clean and dry.  Inspect and verify resins are properly mixed and blended.  Inspect and verify resins are applied to deck within time limits.  Inspect and verify that aggregates are applied uniformly and excess material is cleaned from deck surface.  Document labor and equipment used.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 55

UDOT

Construction Inspection Guide

E) EXPANSION JOINT - SECTION 05832 General This item includes the materials and placement for expansion joints and associated forming, false work, shoring, and concrete headers. Most bridges have joints that are designed and constructed to allow for the bridge to deflect and rotate under traﬃc and to expand or contract with changes in temperature. For smaller bridges under approximately 250 feet or less, “relief joints” are used. For larger bridges (greater than 250) expansion joints are used. Buy American requirements apply for Federally funded projects.

Terminology Expansion joints are available in a variety of configurations. A relief joint is typically a small (appoximately 1/2”) vertical plane that is formed or cut at the end of the deck and approach slab and filled with tar or asphaltic filler to allow for longitudinal movement and rotation. Relief joints are used for smaller bridges and are similar to concrete paving joints. Specifications for relief joints are covered in specification 07922 and other specifications. Simple Expansion Joints are typically used where the movement is between 1-4 inches. The most common system is a Strip Seal Expansion Joint and uses two preformed steel channels that have a neoprene gland that is inserted between the steel rails to allow for expansion. An alternate and less common simple expansion joint is a Rigid Plastic Foam Expansion Joint which includes a preformed (polystyrene) material that is inserted between the two concrete surfaces to allow for expansion. Strip seal and polystyrene joint systems are included in this specification. Structural joints that require several glands or more complex mechanical mechanisms are categorized as Modular Expansion Joints. Modular joints are covered in other specifications. Page | 56

CHAPTER 6: STRUCTURES

CHAPTER 6 Simple expansion joints are manufactured products. Rigid Plastic Foam systems require material certifications. Strip Seal Expansion Joints require material certifications and shop drawings. The Inspector and Resident Engineer are responsible to forward shop drawings to UDOT’s Structures Division for review and approval. In addition, they are responsible to ensure that the joint systems are properly installed.

Submittal Requirements Prior to fabrication and installation, the contractor shall submit the following for approvalal: 1. Material certifications for rigid plastic foam expansion joint systems if used. 2. Material certifications for neoprene glands and structural steel if strip seal expansion joint systems are used. 3. Shop Drawings for approval if strip seal expansion joint systems are used. 4. Concrete mix designs if concrete headers are used separate of the deck concrete.

Common Issues Document and notify a Structural Engineer if these common issues are identified: 1. Shop Drawings are delayed or missing. 2. Approvals, certifications, and inspection not coordinated with Central Materials. 3. Gland systems are damaged. 4. Poor fit. 05832: EXPANSION JOINT

Pre-Inspection  Submit Shop Drawings for approval as per speciﬁcation 05120.  Submit Material certiﬁcations.  Buy America documentation if applicable.

Field Inspection & Documentation  Proper ﬁt. Will not affect expansion, ride or plowing operations.  Gland materials are not torn and do not leak.  Foam systems bonded to concrete surface and do not leak.  Maintain documentation of fabrication, certiﬁcations and placement.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 57

UDOT

Construction Inspection Guide

F) MODULAR EXPANSION JOINT - SECTION 05835 General This item includes the materials and placement for modular expansion joints and associated forming, false work, shoring, and concrete headers. Most bridges have joints that are designed and constructed to allow for the bridge to deflect and rotate under traﬃc and to expand or contract with changes in temperature. For smaller bridges under approximately 250 feet or less, “relief joints” are used. For larger bridges (greater than 250) simple expansion joints are used. For bridges with larger movements, more complex modular expansion joints are used.

Page | 58

CHAPTER 6: STRUCTURES

CHAPTER 6 Joint which includes a preformed (polystyrene) material that is inserted between the two concrete surfaces to allow for expansion. Strip seal and polystyrene joint systems are in other specifications. Structural joints that require several glands or more complex mechanical mechanisms are categorized as Modular Expansion Joints. Modular joints are covered in this section. Modular Expansion Joints require material certifications and shop drawings. The Inspector and Resident Engineer are responsible to forward shop drawings to UDOT’s Structures Division for review and approval. In addition, they are responsible to ensure that the joint systems are properly installed. Buy America requirements apply for Federally funded projects.

Submittal Requirements Prior to fabrication and installation, the contractor shall submit the following for approvalal: 1. Material certifications for steel and reinforcing. 2. Shop Drawings. 3. Concrete mix designs if concrete headers are required.

Common Issues Document and notify a Structural Engineer if these common issues are identified: 1. Shop Drawings are delayed or missing. 2. Approvals, certifications, and inspection not coordinated with Central Materials. 3. Expansion system is damaged. 4. Poor fit. 05835: MODULAR EXPANSION JOINT

Pre-Inspection  Submit Shop Drawings for approval as per speciﬁcation 05120.  Submit Material certiﬁcations for steel and rebar.  Buy America Documentation.

Field Inspection & Documentation  Proper ﬁt. Will not affect expansion, ride or plowing operations.  Material – Concrete Tests for Header Materials.  Forming and bracing plan during installation.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 59

UDOT

Construction Inspection Guide

G) WATERPROOFING MEMBRANE - SECTION 07105 General This item includes procedures for applying a waterproofing membrane for bridge decks and other structural surfaces. Waterproofing membranes are used to create a physical barrier to seal out water and deicing salts. Once applied, the membranes are covered with an asphalt wearing surface. If improperly installed, the waterproofing membranes can trap water and accelerate deterioration of the bridge deck.

Inspection Waterproofing membranes must be applied to a clean, dry deck surface. Without this critical step, the membrane is susceptible to leaking. The first step of the waterproofing membrane system is to clean the deck using a sand blasting operation. Waterproofing membranes are commonly applied for both new construction and deck rehabilitation. The Inspector should ensure that the deck surface has been repaired of any defects prior to sand blasting and applying the membrane. The waterproofing membranes are available in two methods; prefabricated or hot pour. Prefabricated membranes require material certifications and are to be applied to manufacturer’s specifications. For either method, the existing deck surface should be free of sharp edges and protrusions that may damage its ability to seal water. Hot pour membranes are to be applied at specified application rates, thicknesses and temperatures. Prefabricated membranes are applied using primer materials and are to be inspected for bonding, surface defects, and overlap of joints. Either system should be protected from traﬃc until the asphalt overlay has been installed.

Submittal Requirements The following items are required for submittal: 1. Manufacturer’s product data 2. Recommended installation instructions. Page | 60

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues The following are common issues with waterproofing membranes: 1. Existing deck defects are not properly repaired. 2. Sand blasting equipment breaks down. 3. Deck surface is not adequately cleaned. 4. The deck surface is not dry. 5. Primer is not applied properly. 6. Hot pour membranes are not uniformly applied. 7. Resins are improperly mixed by proportion or quickly dispersed. 8. Contractor does not wrap membrane on parapet surfaces. 07105: WATERPROOFING MEMBRANE

Pre-Inspection  Verify sand blasting equipment meets the job size and complexity.  Discuss common issues with contractor prior to applying membrane.  Verify deck surface is clean and dry and free of defects.  Verify material certiﬁcations.

Field Documentation  Inspect and verify shot blasting operations.  Inspect and Verify deck is clean and dry.  Inspect and verify hot pour membranes are applied uniformly.  Inspect and verify preformed membranes are properly placed with overlap dimensions.  Protect membrane from trafﬁc until asphalt overlay is placed.  Document labor and equipment used.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 61

UDOT

Construction Inspection Guide

6.6 STRUCTURAL REPAIRS AND MODIFICATIONS

A) APPROACH SLAB JACKING - SECTION 03605 General This item includes the materials and construction requirements for lifting (jacking) of bridge approach slabs. Approach slabs are installed on most bridges to provide a smooth transition between the bridge and pavements. As a bridge is constructed, the fill materials behind the abutments often settle with time creating a void or settlement of the approach slabs. These voids can be filled and the approach slab lifted by injecting a cement or urethane material. This specification relates to the materials and construction methods for cement based materials. Special provisions should be reviewed for urethane materials.

Construction and Inspection Approach slab jacking consists of drilling a 1-2â&#x20AC;? diameter hole through the approach slab, attaching a nozzle and injecting a concrete grout material to fill the void and lift the approach slab. Inspector responsibilities include review and approval of the materials, mixing of the grout, drilling of holes, injection, finished profile (ride), and clean up processes. Some newer approach slabs use post-tensioned cables. Drilling of these approach slabs should only be done with the review and approval of a Structural Engineer.

Page | 62

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues The following are common issues with approach slab jacking: 1. Concrete/grout materials do not have approved mix design. 2. Reinforcing steel is damaged during drilling process. 3. Contractor lifts the approach slab too high (poor ride). 4. Contractor uses more materials than expected. 5. Contractor does not clean up waste materials. 6. Materials tests do not meet requirements. 7. Excessive cold, heat or weather conditions. 03605: APPROACH SLAB JACKING

Pre-Inspection  Contractor to Submit concrete mix design for approval.  Contractor to give prior notice of schedule for inspection & material testing.  Inspector to ensure adequate equipment for mixing and injecting.  Inspector to ensure reinforcement in proper placement.  Ensure approach slab does not have post tensioning strands.

Field Documentation  Ensure concrete meets air entrainment and slump requirements.  Ensure that mixing and pumping equipment is properly used.  Ensure that drilling does not damage reinforcing steel.  Inspect injection process and lifting of panels to avoid raising panels too high.  Document materials, labor and equipment used.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 63

UDOT

Construction Inspection Guide

B) STRUCTURAL CONCRETE REPAIR

AND

SEALING - SECTION 03924

General This item includes the materials and construction requirements for repairs and rehabilitation to structural concrete. Common structural items include columns, piers, pier caps, abutments and other exposed concrete surfaces. Concrete deck repairs are covered under other specifications.

Construction and Inspection Rehabilitation and repairs of structural concrete vary for each bridge. Repairs may be intended to gain a few additional years of life or to provide extensive rehabilitation. The Inspector needs to adequately review the intent of the plan package and exercise judgment during the construction process for approval, extent (scope) of work and anticipated results. The Inspector should discuss questions and concerns with the design Engineer if needed. Most structural concrete repairs include removing delaminated or damaged concrete, cleaning and repairing reinforcing steel, and placing new concrete materials over the repaired areas. The Inspector should ensure that the requirements of the plans and special provisions are met. The Inspector should ensure that jackhammers and other equipment used to remove deteriorated concrete does not damage surrounding concrete and structural items. Any exposed reinforcing steel needs to be inspected to ensure that it has been properly sandblasted, cleaned and repaired prior to patching with new concrete materials. Concrete patching materials need to be approved and inspected to ensure they will bond with the existing concrete and have an acceptable finish.

Page | 64

CHAPTER 6: STRUCTURES

CHAPTER 6

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Equipment list and methods for removal of deteriorated concrete. 2. Material Certifications or mix design for concrete patching materials, crack injection materials, and concrete seals. 3. Certifications of labor for epoxy injection operators. 4. Girder jacking and shoring plan for beam end repairs. 5. Prior notification of schedule to remove and place new concrete materials.

Common Issues The following are common issues with approach slab jacking: 1. Concrete/grout materials do not have approved mix design. 2. Reinforcing steel or surrounding concrete is damaged during removal process. 3. Quantity overages if paid by the quantity. 4. Does not remove enough deteriorated areas if paid by lump sum. 5. Poor finish and bonding of new patching materials. 6. Contractor does not clean up waste materials. 7. Materials tests do not meet test requirements. 8. Excessive cold, heat or weather conditions. 03924: STRUCTURAL CONCRETE REPAIR & SEALING

Pre-Inspection  Contractor to Submit material certiﬁcations or mix designs.  Contractor to give prior notice of schedule for inspection & material testing.  Inspector to ensure properly sized equipment for removal, and repairs.  Certiﬁcations of labor for epoxy injection.  Girder shoring and lifting plans if required.

Field Documentation  Ensure removal does not damage surrounding concrete or structure.  Ensure that proper equipment is used.  Ensure that materials meet speciﬁcations.  Verify and document quantities of areas to be repaired. Document labor, equipment, and materials used.  Ensure bonding and ﬁnish of patching materials.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 65

UDOT

Construction Inspection Guide

C) SLOPE PROTECTION REPAIR - SECTION 03932 General This item includes the materials and construction requirements for repairing slope protection on bridge structures. Slope protection is commonly used to eliminate erosion on the slopes underneath a bridge structure. They are typically made of concrete and reinforced with a welded wire fabric. Slope protection occasionally settles or becomes damaged requiring repair. Most repairs involve the replacement of several panels as specified in the plan package.

Construction and Inspection The extent of slope protection repairs can vary from a few panels to an entire slope. The Inspector must exercise judgment in the field to verify actual quantities to be repaired. Slope protection deterioration is typically caused by water undermining the concrete. Any repairs should also consider the correcting the source of the erosion such as damaged deck drains. Slope protection repairs typically involve removing the damaged concrete, repairing underlying bedding materials, placing welded wire reinforcement and casting new concrete. The welded wire fabric and concrete are covered in other specifications. Inspector responsibilities include review and approval of the materials, satisfactory removal of damaged areas, preparing a stable grade, proper placement of the reinforcement, and finishing of new concrete.

Page | 66

CHAPTER 6: STRUCTURES

CHAPTER 6

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Concrete Mix Design for approval by the Engineer. 2. Certifications for welded wire fabric and granular borrow. 3. Prior notification of schedule to place concrete and notification to Inspectors and materials testing personnel. 4. The Engineer must give approval and notice to proceed with concrete placement prior to performing work.

Common Issues The following are common issues with approach slab jacking: 1. Concrete/grout materials do not have approved mix design. 2. Underlying drainage problems that require additional repairs. 3. Quantities in field are greater than shown on plans. 4. Finishing problems due to slope and wrong slump of concrete. 5. Reinforcing fabric is not placed properly. 6. Contractor does not clean up waste materials. 7. Materials tests do not meet requirements. 8. Excessive cold, heat or weather conditions. 03932: SLOPE PROTECTION REPAIRS

Pre-Inspection  Contractor to Submit concrete mix design for approval.  Contractor to give prior notice of schedule for inspection & material testing.  Contractor to submit certiﬁcations for materials.  Inspector to verify plan quantities and locations before removal process starts.

Field Documentation  Ensure concrete meets air entrainment and slump requirements.  Ensure that mixing and pumping equipment is properly used.  Ensure base materials and drainage issues have been properly repaired.  Ensure welded wire fabric has been properly placed.  Ensure concrete is properly placed and ﬁnished.  Document materials, labor and equipment used.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 67

UDOT

Construction Inspection Guide

D) PARAPET END MODIFICATIONS - SECTION 03933 General This item includes the materials and construction requirements for modification repairs to bridge parapet ends. Many older bridges have parapets (concrete barrier) that do not meet current safety standards. As a result, these parapet ends are commonly retrofitted to improve the safety features.

Construction and Inspection Modifications and rehabilitation of bridge parapets vary for each bridge and project. The Inspector needs to adequately review the intent of the plan package and exercise judgment during the construction process for approval, scope of work and anticipated results. The Inspector should discuss questions and concerns with the design Engineer if needed. Most parapet ends modifications involve removing a portion of the concrete parapet and attaching upgraded guardrail or barrier. Connection details are an important aspect of these repairs. The Inspector is responsible to ensure that safety considerations are met as well as the use of proper materials and construction practices.

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Equipment list and methods for removal of existing parapet concrete. 2. Manufacturers Certifications and instructions. 3. Material Certifications. 4. Prior notification of schedule to remove and place new concrete materials.

Page | 68

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues The following are common issues with parapet end modifications: 1. Concrete materials do not have approved mix design. 2. Reinforcing steel or surrounding concrete is damaged during removal process. 3. Quantity overages if paid by the quantity. 4. Improper fit or placement of anchor bolts, and connection details. 5. Poor finish of concrete. 6. Contractor does not clean up waste materials. 7. Materials tests do not meet test requirements. 8. Excessive cold, heat or weather conditions. 03933: PARAPET END MODIFICATION

Field Documentation  Ensure removal does not damage surrounding concrete or structure.  Ensure that proper equipment is used.  Ensure that materials meet specifications.  Ensure anchors and connection details are properly placed.  Ensure guardrail or concrete barrier is attached properly  Verify and document quantities of areas that are modified including labor, equipment, and materials used.  Ensure bonding and finish of patching materials.

E) STRUCTURAL POTHOLE PATCHING - SECTION 03934 General This item includes the materials and construction requirements for repairs, rehabilitation for patching of potholes on bridge decks. Concrete deck repairs are one of the most common repairs for a bridge structure. Membranes and overlays systems are typically used with pothole repairs and are covered in other specifications.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 69

UDOT

Construction Inspection Guide

Construction and Inspection Rehabilitation and repairs of concrete decks vary for each bridge. Repairs may range from a few square yards to the entire deck surface. Deck repairs are intended to improve the ride and increase the life of the bridge. In many cases, the extent of the repairs required is not known until work begins. The Inspector needs to adequately review the intent of the plan package and exercise judgment during the construction process for approval, extent (scope) of work and anticipated results. The Inspector should discuss questions and concerns with the design Engineer if needed. The deteriorated areas to be repaired are typically identified on the plan sheets. The Inspector should verify these locations and look for additional areas of delaminated concrete. Delaminated areas can be found by â&#x20AC;&#x153;soundingâ&#x20AC;? the deck surface with a steel rod, hammer or dragging a steel chain. Most structural concrete deck repairs include removing delaminated or damage concrete, cleaning and repairing reinforcing steel, and placing new concrete patching materials over the repaired areas (pothole repairs). Deteriorated concrete can be removed by the use of jackhammers or pressurized water. The Inspector should ensure that the requirements of the plans and special provisions are met. The Inspector should ensure that jackhammers and other equipment used to remove deteriorated concrete does damage surrounding concrete and structural items. Any exposed reinforcing steel needs to be inspected to ensure that it has been properly sandblasted, cleaned and repaired prior to patching with new concrete materials. Concrete patching materials need to be approved and inspected to ensure they will bond with the existing concrete and have an acceptable finish.

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Equipment list and methods for removal of deteriorated concrete. 2. Plan for handling of waste water. Page | 70

CHAPTER 6: STRUCTURES

CHAPTER 6 3. Material Certifications or mix design for concrete patching materials, crack injection materials, and concrete seals. 4. Prior notification of schedule to remove and place new concrete materials.

Common Issues The following are common issues with concrete deck pothole repairs: 1. Equipment is too big and damages surrounding concrete. Jackhammers too big or water pressure is too high. 2. Concrete/grout materials do not have approved mix design. 3. Quantity overages if paid by the quantity. 4. Does not remove enough deteriorated areas if paid by lump sum. 5. Poor finish and bonding of new patching materials. 6. Contractor does not clean up waste materials. 7. Materials tests do not meet test requirements. 8. Excessive cold, heat or weather conditions. 9. Deck blow through. 03934: STRUCTURAL POTHOLE PATCHING

Pre-Inspection  Contractor to Submit material certiﬁcations or mix designs.  Contractor to give prior notice of schedule for inspection & material testing.  Contractor to submit removal plan including equipment to be used.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 71

UDOT

Construction Inspection Guide

F) EXPANSION JOINT MODIFICATION - SECTION 05832 General This item includes the materials and construction requirements for the replacement of bridge expansion joint systems. As a bridge ages, the expansion joint systems deteriorate and require replacement to allow the bridge to properly expand with temperature changes and to also seal water from leaking onto other portions of the bridge. Related sections including structural concrete and structural steel are covered in other specifications.

Construction and Inspection Rehabilitation and repairs of concrete decks typically include the removal and replacement of expansion joint systems. Repairs involve saw-cutting and removing a portion of the surrounding concrete, removal of the existing joint system, forming, installation of a new joint system and casting of new header concrete. Joint systems are typically manufactured by one of two national suppliers who will submit shop drawings for the new joint system. The Inspector needs to ensure: 1. That surrounding concrete and structural items are not damaged during the removal process. 2. Materials are certified, and shop drawings are approved. 3. New system is constructed to the dimensions and other requirements of the plan package. 4. Special consideration should be given to installing the joint system to match temperatures during construction and for a smooth fit that will not be damaged by plows or traďŹ&#x192;c. Surrounding concrete is typically removed with jackhammers. The Inspector should ensure that jackhammers and other equipment used to remove deteriorated concrete do not damage surrounding concrete and structural items. Any exposed reinforcing steel needs to be inspected to ensure that it has been properly sandblasted, cleaned and repaired prior to patching with new concrete materials. Concrete header materials need to be approved and inspected to ensure they will bond with the existing concrete and have an acceptable finish. Page | 72

CHAPTER 6: STRUCTURES

CHAPTER 6

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Equipment list and methods for removal of adjacent concrete deck. 2. Plan for handling of waste water during saw-cutting. 3. Shop drawings for new expansion joint system. 4. Material Certifications or mix design for concrete header materials, crack injection materials, and concrete seals. 5. Prior notification of schedule to remove and place new concrete materials.

Common Issues The following are common issues with expansion joint modification repairs: 1. Equipment is too big and damages surrounding concrete. 2. Concrete header materials do not have an approved mix design. 3. Poor finish and bonding of new patching materials. 4. Poor fit and ride issues with new joint system. 5. New joint system not set to ambient temperatures. 6. Contractor does not clean up waste materials. 7. Material tests do not meet test requirements. 8. Excessive cold, heat or weather conditions. 05832: EXPANSION JOINT MODIFICATION

Pre-Inspection  Contractor to Submit material certiﬁcations or mix designs.  Contractor to submit shop drawings for new joint system.  Contractor to give prior notice of schedule for inspection & material testing.  Contractor to submit removal plan including equipment to be used.

Field Documentation  Ensure removal does not damage surrounding concrete or structure.  Ensure that proper equipment is used.  Ensure that materials meet speciﬁcations.  Verify new joint system is installed to plan dimensions.  Ensure bonding of new concrete to surrounding concrete.  Document labor, equipment, materials and time to complete item.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 73

UDOT

Construction Inspection Guide

G) SEALING EXISTING CONCRETE SLOPE PROTECTION JOINTS - SECTION 07921 General This item includes the materials and construction requirements for sealing of existing concrete bridge slope protections. Reinforced concrete slope protections are used to protect soils and underlying earthwork near bridge abutments from erosion. As time passes and the concrete slope protection ages, cracks and openings often appear at joints. Left unrepaired, these openings can cause water to undermine the concrete and for the slope protection to settle and fail. To prevent this, existing concrete slope protections are often repaired and resealed. Slope protection repairs are covered in other specifications. This specification relates to the sealing materials and installation.

Construction and Inspection The extent of slope protection repairs can vary from a few panels to an entire slope. Once repairs are made, the joints and cracks are resealed using pre-manufactured backer material and caulking sealant materials. The backer materials are a foam type material and are covered in other specifications. The sealant is a pre-manufactured polyurethane material that is shipped in common caulking tube containers. The Inspector is responsible to ensure that materials meet specifications, surfaces are clean and prepared, and the sealant is properly installed. Material certifications are required for submittal and approval prior to installation. The Inspector should visually review and approve concrete surfaces to ensure that weeds and debris have been removed so that the sealant will adhere to the surfaces. The Inspector is also responsible to ensure that the joints and cracks are filled with a uniform application of the sealant and finished to match the exposed surfaces. Excess materials should be cleaned. Typical areas that require sealant include slope protection grid joints, joint surface with the abutment and wingwalls and repairs of cracks. This item is typically paid by the amount of material placed. The Inspector needs to maintain daily records of production including labor, equipment and materials used. Page | 74

CHAPTER 6: STRUCTURES

CHAPTER 6

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Certifications for backer rod materials. 2. Certifications of sealant materials. 3. Installation Plan (labor, equipment and materials).

Common Issues The following are common issues with concrete slope protection sealing: 1. Backer Rod or Sealant materials have not been approved. 2. Surfaces have not been properly cleaned or are not dry. 3. Weather, dryness and temperature. 4. Insuﬃcient or excessive application of material. 5. Contractor does not clean up after completion of work. 07921: SEALING EXISTING CONCRETE SLOPE PROTECTION JOINTS

Pre-Inspection  Contractor to submit material certiﬁcations for approval.  Contractor to give prior notice of schedule for inspection.  Contractor to submit installation plan.  Inspector to verify locations before installation.

Field Documentation  Ensure concrete surfaces have been properly prepared and are clean.  Ensure that proper equipment is used.  Ensure backer rod is installed where appropriate.  Ensure sealant material is uniformly and neatly installed.  Ensure clean up of waste materials.  Document materials, labor and equipment used.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 75

UDOT

Construction Inspection Guide

H) RELIEF JOINT CRACK SEALING - SECTION 07922 General This item includes the materials and construction requirements for sealing of concrete relief joints on bridges and other structures. Concrete relief joints are commonly used on smaller bridges where the approach slab meets the bridge deck and where the approach slab meets the adjacent pavement. Relief joints are typically a Â˝" small vertical joint that is formed or saw cut to allow expansion of the structure. To prevent water intrusion these joints are filled with backer rod and a hot applied asphaltic (tar) material.

Construction and Inspection The installation process includes preparing the joint surface to ensure it is clean and free of debris, installation of a backer rod and placement of a hot applied joint material. The Inspector is responsible to ensure the quality of materials and installation of this process. The contractor should also review a placement plan with the Inspector including labor, equipment and materials to be used. Backer rod and sealant materials require material certifications. The Inspector should visually inspect and verify that the surfaces have been cleaned of existing sealant and debris. Backer rods should be inspected to ensure that they are not damaged and installed to the proper depths and dimensions. Hot applied sealants should be inspected for proper heating and equipment to apply. The sealant should be applied in a uniform rate that does not under or over fill the void. This item is typically paid by the amount of material placed. The Inspector needs to maintain daily records of production including labor, equipment and materials used.

Submittal Requirements Prior to installation, the contractor shall submit the following for approval: 1. Certifications for back rod materials. 2. Certifications for sealant materials. 3. Installation Plan (labor, equipment and materials). Page | 76

CHAPTER 6: STRUCTURES

CHAPTER 6

Common Issues The following are common issues with relief joint sealing: 1. Backer Rod or Sealant materials have not been approved. 2. Insuﬃcient equipment or labor to install. 3. Surfaces have not been properly cleaned or are not dry. 4. Weather, dryness and temperature. 5. Insuﬃcient or excessive application of material. 6. Contractor does not clean up after completion of work. 07922: RELIEF JOINT CRACK SEALING

Pre-Inspection  Contractor to submit material certiﬁcations for approval.  Contractor to give prior notice of schedule for inspection & material testing.  Contractor to submit installation plan.  Inspector to verify locations before installation.

I) CLEANING

AND

REPAINTING STRUCTURAL STEEL - SECTION 09991

General This item includes specifications for the materials and application of cleaning and repainting systems for structural steel. Structural steel painting is performed primarily to extend the life of a structure by slowing the corrosion process. This specification is for repainting systems. Requirements for new painting systems are covered in other specifications.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 77

UDOT

Construction Inspection Guide

The life of a paint system and its ability to slow corrosion are determined by the quality of the materials and how well they are applied. The Inspector is responsible to ensure that these two conditions are met. In addition, the Inspector needs to ensure that the paint systems do not adversely aﬀect the environment, worker safety, or the traﬃc operations.

Painting Plan The contractor is required to submit for approval a comprehensive painting quality plan that includes the following: • Painting Protection plan that includes environmental protection plans, and overspray protection plans. • Safety Plan for worker exposure and fall protection. • Source, gradation and procedures for sandblasting and surface preparation. • Type and source of solvents and thinning agents. Material information and data for each component of the 3 part paint system. This shall include film thickness requirements, Product Safety Data, thinning requirements, temperature requirements, surface profile (roughness) requirements, mixing instructions and equipment recommendations. Page | 78

CHAPTER 6: STRUCTURES

CHAPTER 6

Materials Acceptance In addition to the requirements of the painting quality plan, the contractor and material suppliers are required to submit certifications and samples of paint systems for testing, review and approval to UDOTâ&#x20AC;&#x2122;s Central Materials Paint lab. UDOT will test paint samples from each batch or lot prior to use and will reject or approve paints in comparison to standards.

Construction Inspection The Inspector is responsible to verify the painting process including surface preparation, mixing and blending of paints, application of paint system, safety, equipment and environmental impacts. The Inspector shall verify that surfaces are clean and have a surface profile that will allow paint to adequately bond to the steel surface. The Inspector will also verify application rates, mill thicknesses, uniformity and quality of the applied paint. Submittal Requirements The contractor shall submit the following for approval: 1. Project Schedule with milestones for painting operations. 2. Paint Plan including: Environmental protection plan, safety plan, materials source and data, sandblasting operations, test samples and a quality plan. 3. Approval of paint samples by UDOT Central Materials. 4. Certification of Painters and Sandblasters.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 79

UDOT

Construction Inspection Guide

Field Documentation  Field pre-qualify painters using test area.  Verify enforcement of safety plan, including scaffolding, fall protection and work experience.  Ensure paint and other materials are properly shipped and stored.  Provide readily available MSDS sheets and product information.  Ensure surfaces are clean and prepared to acceptable proﬁle and free of debris and dust.  Measure application rates, thicknesses and processes for applying paint.

J) CLEANING

AND

OVERCOATING STRUCTURAL STEEL - SECTION 09992

General This item includes specifications for the materials and application for cleaning and overcoating of existing paint systems for structural steel. Structural steel painting is performed primarily to extend the life of a structure by slowing the corrosion process. This specification is primarily intended for spot repairs and overcoating of existing paint systems to extend the life of the existing paint system rather than replacing it. Requirements for new and replacement painting systems are covered in other specifications. The life of a paint system and its ability to slow corrosion are determined by the quality of the materials and how well they are applied. The Inspector is responsible to ensure that these two Page | 80

CHAPTER 6: STRUCTURES

CHAPTER 6 conditions are met. In addition, the Inspector needs to ensure that the paint systems do not adversely aﬀect the environment, worker safety, or the traﬃc operations.

Paint Systems Painting of structural steel does not use a single paint with several coats, but rather a “paint system” that includes proper surface preparation, several coats of diﬀerent materials, and defined application procedures. UDOT follows general requirements established by the Northeast Protective Coatings Committee (NEPCOAT). A 3 part coating system is required consisting of a zinc primer, epoxy or urethane intermediate coat, and aliphatic urethane top coat. Diﬀerent colors are specified and required for each coat to assist in visual inspection of the coverage. Localized areas may require removal and replacement using a 3 part coating systems (prime, intermediate and top coats). However the majority of the existing paint system will be cleaned and overcoated with 2 coats (intermediate and top coats). Specific areas requiring replacement versus overcoating are typically identified in the plan package, but require verification in the field by the Inspector and Engineer.

Materials Acceptance In addition to the requirements of the painting quality plan, the contractor and material suppliers are required to submit certifications and samples of paint systems for testing, review and approval from UDOT’s Central Materials Paint lab. UDOT will test paint samples from each batch or lot prior to use and will reject or approve paints in comparison to standards.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 81

UDOT

Construction Inspection Guide

Painter and Sandblaster Qualifications The painter and sandblaster are required to be certified by the Society of Protective Coatings (SSPC) prior to the contract award. Diﬀerent certifications are required for painters and sandblasters and for field work and shop work.

Construction Inspection The Inspector is responsible to verify the location of areas to receive paint replacement and overcoating. The Inspector is also responsible to ensure the painting process including surface preparation, mixing and blending of paints, application of paint system, safety, equipment and environmental impacts. The Inspector verifies that surfaces are clean and have a surface profile that will allow paint to adequately bond to the steel surface. The Inspector verifies application rates, mill thicknesses, uniformity and quality of the applied paint.

Common Issues Common issues that the Inspector and Resident Engineer may encounter include: 1. Contractor does not submit all requirements of the painting plan. 2. Paint or sandblasting materials do not meet standards or tests. 3. Contractor does not adequately protect workers from paint and sandblasting hazards. 4. Contractor does not adequately protect surrounding environment or traﬃc from overspray. 5. Surface is not adequately cleaned or does not have an eﬀective surface profile for the paint system to bond to. 6. Paint is applied at improper application rates, thicknesses or lacks uniformity Page | 82

CHAPTER 6: STRUCTURES

CHAPTER 6 09992: CLEANING & OVERCOATING STRUCTURAL STEEL

Field Documentation  Field pre-qualify painters using test area.  Verify enforcement of safety plan, including scaffolding, fall protection and work experience.  Ensure paint and other materials are properly shipped and stored.  Ensure surfaces are clean and prepared to acceptable proﬁle and free of debris and dust.  Measure application rates, thicknesses and processes for applying paint.

UTAH DEPARTMENT OF TRANSPORTATION

Page | 83

Construction Inspection Guide Chapter Links

1-Preface & Introduction

2-Traffic Control

3-Demolition and Earthwork

4-Drainage

5-Pavement & Materials

6-Structures

7-Traffic Signals, Lighting, ATMS

8-Striping, Signing, Safety Features

9-Landscaping, Fencing, Incidental Const.

10-Utilities

11-PDBS

12-Crash Cushion & Barrier End Treatments

Construction Inspection Guide

udot.utah.gov/go/construction